June 25, 2026 15:21

At Plast 2026 in Milan, BASF showcased Ultramid Expand, an injection moulding foam material developed two years ago but so far given little publicity.

It is a polyamide-based foam made from pre-expanded particles with controlled size and density. According to the German group, these particles bond together to form complex three-dimensional components without generating waste during the moulding process.

The main area of application, with interesting developments is the automotive sector, where demand is strong for materials that combine mechanical properties with low weight. Potential applications have been identified in impact absorbers, protection and energy-management components, and lightweight solutions for electric mobility.

“In Italy, we are supplying it to premium automotive brands for cars used on track, which, given the high speeds involved, require a lightweight material able to withstand extreme conditions,” Filippo Sola (pictured), Senior Sales Manager for Engineering Plastics at BASF in Italy, said at the exhibition. “With Ultramid Expand, components can be moulded with isotropic mechanical properties, uniform in all directions, without chemical reactions during processing,” he added.

The properties cited by the producer make this foam suitable for high-performance technical applications. These include resistance to high temperatures, making it compatible with body-in-white processes in the automotive industry, as well as stiffness and mechanical strength provided by its closed-cell structure. The material also offers high chemical resistance, particularly to fuels, oils and lubricants.

A further strength of Ultramid Expand is the possibility of producing mono-material components, which are easier to recover at the end of life, an aspect that is becoming increasingly important in the automotive sector.

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