In thermoplastic processing, foaming problems can make life difficult in the production phase. That's why our 35 years of expertise goes into every single Expancel Microsphere, giving you closed cell structuring that lets you control the foaming during your process. This leaves you in total control when adding volume to your matrix. The closed cell structure of the foam prevents water absorbtion - making Expancel ideal when used in injection molded shoe soles, insulation-type applications and much more.

Our microspheres can be used in applications with process temperatures up to 235°C (455°F). Either as a blowing agent on its own, or combined with physical or chemical blowing agents. It can be found in PVC, TPR, TPU and rubber - across a wide range of thermoplastic applications used all over the word. The advantages it delivers will help you achieve lighter products with higher quality in thermoplastics.

Bursting with benefits in thermoplastics

  • Avoid sink marks and voids in molded shoe soles
  • An easy flowing matrix enhances expansion capacity enabling low density even at low addition levels
  • Low in density and weight with up to 40 times in volume comparing to other materials.
  • Aesthetically appealing, matt rubber finish

These benefits are merely the tip of the iceberg of what Expancel brings to your process. It can also be used in a wide range of binder systems which are applied on the substrate by impregnation, coating, spraying or lamination.

Thermosplastic processing methods with Expancel

No expensive equipment or licensing necessary. Just add Expancel.

Injection molding
Add Expancel microspheres to the mix and easily achieve density reduction levels between 10-30% in injection molding.

Extrusion
Usable in almost every type of extrusion line, our microspheres help you reach perfect expansion in profiles, hoses, sheets, cables and more.

Thermoforming
Expanded microspheres withstands the thermoforming stage to give you a brilliantly foamed product. Both thin and thick sheets foamed with Expancel leads to feasible thermoforming of e.g. PS and PP.

Blow molding
Make foamed parts with blow molding processes, but note that adjustments might be necessary on blow pressure to reach low densities.

Calendering
Produce beautifully foamed sheets of e.g. PVC in calendaring processes.

Product selection for thermoplastic applications

Product groups Characteristics Main applications
Expancel DU Dry. Unexpanded For applications where no water can be added: industrial nonwoven textiles, underbody coatings & sealants, silicone rubber, shoe soles, etc.
Expancel MB Masterbatch. Dry. Unexpanded Masterbatch, mixed with a carrier. Used in thermoplastic applications where Expancel’s closed cells and uniform cell structure gets optimum results.
Expancel FG Foodgrade. Dry. Unexpanded Dry, unexpanded and as Masterbatch. Used in food packaging applications such as wine corks, cap seals, packaging and more.

Contact us about Expancel

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We have an R&D organization with the capabilities and expertise to maximize the benefits of Expancel in your application.