New lightweight construction solution: Great potential for the transportation sector
Foamed ABS material for bus interior wins innovation award
The material Maywoflamm® ECE Lightweight from Röchling Industrial has been awarded the Innovation Award at this year's Fakuma. A jury of experts awarded the new development second place in the extrusion category. Melissa Sokoli, Application and Process Engineering at Röchling Industrial Allgäu GmbH and technical project manager, helped develop the product. In this interview, she provides insights into the development process, explains the added value of Maywoflamm® ECE Lightweight for the market and what the Innovation Award means for the Röchling team.
Congratulations on the award. What does it mean for you as a development team?
Melissa Sokoli: Thank you, the Innovation Award is a very special recognition for us. A lot of joint development work went into the project, because we saw great potential in the product from the very beginning. We are pleased that our solution was able to prevail among more than 150 submissions and achieved second place. It shows us that the intensive work has paid off. At the same time, this award encourages us for the future: It confirms our path and motivates us to consistently drive forward the development of the product.
How did the idea for Maywoflamm® ECE Lightweight come about and what was your goal?
Melissa Sokoli: The first idea came from a long-standing customer. Against the background of the increasing electrification of bus transport and the associated increase in the weight of these vehicles, we also recognised the need for a suitable solution. Our goal was to develop a lightweight and flame-retardant material that meets all necessary technical requirements.
What exactly is Maywoflamm® ECE Lightweight and how does it differ from previous solutions on the market?
Melissa Sokoli: Maywoflamm® ECE Lightweight is a foamed and thermoformable ABS. The material is more than 20 percent lighter than a comparable solid plate, while the mechanical properties, surface, colour and feel remain unchanged. Maywoflamm® ECE Lightweight meets the high requirements for flame retardancy and mechanical resilience and thus offers a high-performance, weight-optimised alternative for modern bus conversion.
Previous solutions are often much heavier. If lightweight construction approaches are pursued, composite systems are often used that are difficult or impossible to recycle and also do not offer the same possibilities for thermoforming. Maywoflamm® ECE Lightweight, on the other hand, combines low weight with the usual product properties, the required thermoformability and, as a thermoplastic material, it offers the opportunity to recycling.
What challenges did you face during development?
Melissa Sokoli: One of the biggest challenges was developing the material in such a way that it could be produced economically on our existing machinery. To do this, we had to establish a stable production process. Especially during foaming, the materials react very sensitively to the smallest process fluctuations. We did a lot of testing and further developed the material in order to precisely coordinate all parameters and ensure consistently high quality.
What added value does the material offer customers?
Melissa Sokoli: Our customers can reduce the weight of their components by more than 20 percent without compromising on appearance, feel or functionality. Especially in electromobility, every kilogram saved counts. At the same time, less raw material is required and, as a thermoplastic material, the product offers the option of recycling. Maywoflamm® ECE Lightweight is made entirely of ABS and offers, sorted by type, the possibility of recycling. We see this as a significant advantage over many lightweight sandwich solutions on the market. In this way, we combine the advantages of lightweight construction with the responsible use of valuable resources and create the basis for a sustainable material cycle.
What potential do you see for lightweight technology in the future and are further developments already planned?
Melissa Sokoli: We see great potential for the entire transportation sector. In addition to bus interiors, interior trim for caravans and vans, for example, are also possible areas of application. Wherever weight can be saved, our solution offers advantages.
In the long term, we also want to offer solutions for rail transport and develop a material with the corresponding flame-retardant requirements. That's exactly what makes it exciting for me: We have already taken an important step, but at the same time we still see many opportunities for future developments. I look forward to further explore this potential together with the team.
