David Howgego, Business Development Manager at MGR Foamtex, says that the strategic relationship with Zotefoams is key to the company’s success. Zotefoams’ ZOTEK® F OSU range of high-performance lightweight aviation foams produced from PVDF have been used in the advanced MGR SoftWall® panel system for over a decade – this unique vertical soft wall panel system is designed to cocoon the passenger, increasing comfort and deadening sound.

The latest addition to the ZOTEK F OSU range – the Extra-Rigid XR grade – is the backbone of the new MGR SoftWall NextGen range, which, says David Howgego, is all about weight reduction. As a semi-structural foam, ZOTEK F OSU XR allows MGR Foamtex to offer all the benefits of MGR SoftWall but at half the weight.

Advanced Zotefoams materials are used to create many components, in this case a bespoke backshell for a business class seat. The key element is the XR grade foam, which replaces the traditional solid thermoplastic structure to achieve significant weight savings. During the manufacturing process, this is overlaid with a decorative front layer made from ZOTEK F SR (Semi-Rigid) Decorative front layer is made from SR and finally a face fabric is applied to produce the finished MGR SoftWall NextGen panel.

Ross Latham, Deputy Engineering Manager at MGR Foamtex, emphasises the importance of the company’s close partnership with customers to achieve a high-quality bespoke finished product, with constant communication, agreed milestones and assembly trials. Most parts, he says, include at least two grades form the ZOTEK F OSU range.

The process begins with vacuum forming a flat sheet of XR. 

Working with customers 3D CAD is used to create and refine designs that add individuality and a luxurious feel to Business and First cabins. Once approved, the design is applied to the ZOTEK F OSU SR via CNC routing.

From here, MGR Foamtex’s expert craftsmen hand finish each part in a process known as trimming. Using specialist adhesives, the two layers of ZOTEK F are bonded together before the chosen face fabric is applied, bringing the bespoke designs to life.

The result – MGR SoftWall NextGen: 50% lighter thanks to Zotefoams’ unique ZOTEK F materials.

Find out more about ZOTEK® F OSU.

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Now these same properties are being harnessed in a new application where safety is also paramount. Breakaway doors are used in medical facilities to protect vulnerable patients from self-harm while affording privacy.

Kennon Products (Wyoming, USA) recently launched its Kennon Door 2.0, its newest ligature-resistant patient safety product, featuring ZOTEK F. The door’s soft materials and breakaway magnetic hinge save lives, while its durable design enhances the look of any facility.

A primary objective for Kennon was to develop a door that would achieve the new National Fire Protection Association NFPA-286 certification, which is required for facility operators wishing to meet certain fire prevention guidelines.

Zotefoams worked closely with Kennon to select and test various ZOTEK F materials, while providing support and insight based on previous experience of aviation applications and flame testing. For Zotefoams, this process resulted in the development of a new product.

For Kennon, it was mission accomplished, with the successful launch in 2022 of its Door 2.0, the first anti-ligature door offering NFPA-286 certification.

Find out more about Zotek F

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Thermoforming expert Plastika Balumag (Hochdorf, Switzerland) produces parts for a wide range of aviation applications, including window blinds, back coverings for seats, instrument panel coverings and other critical components. The most innovative example is a formed, self-insulating air duct assembly, which optimises air circulation through the on-board ventilation system. Conventionally, ventilation circulation systems are comprised of both rigid ducts, derived from heavier polycarbonate materials, and separate insulation products, which add further weight.

Manufactured using naturally inert polymer materials, ZOTEK F also boasts exceptional safety credentials. With outstanding fire, smoke and toxicity properties, ZOTEK F was selected as the preferred material for Plastika Balumag’s air ducts.

Also resistant to UV light, which is far more intense at high altitude, ZOTEK F is a material of choice across several other critical applications throughout the aircraft such as in interior finishes and wall panels.

ZOTEK F OSU XR is an extra-rigid closed cell crosslinked foam with structural and semi-structural capabilities: It is used extensively by leading aircraft manufacturers globally for window seals, soft-touch trim, close-outs, insulation, carpet underlay and environmental control systems. For Plastika Balumag, ZOTEK F OSU XR was the only lightweight alternative that met all the criteria for the application, while adhering to stringent aviation certification requirements.

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Plastazote MP15FR delivers best-in-class flammability credentials along with incomparable lightweight properties, guaranteeing a cost-effective solution to saving energy. It also has exceptional vibration absorption capabilities that give superior comfort to passengers. 

Various insulation materials had been tested as an alternative, in both dry and wet conditions and, while with SSC-Q1 constructed with MP15FR the deviation of the insulation value is in the single-digit percentage range, the values for open-cell materials in wet conditions deviate by up to 74% of the specified value, significantly reducing insulation performance.

SSC spokesperson comments, “If a vehicle is equipped with open cell insulation and it becomes damp or wet – which will happen sooner or later – the material loses its insulation properties and energy costs rise dramatically.”

They continue, “SSC-Q1 is not influenced by moisture or temperature fluctuations, so thanks to the constant insulation properties of Plastazote MP15FR, energy-efficient travel is possible.”

Headquartered in Goldach, Switzerland, SSC specialises in the development and production of innovative concepts and system components for railway vehicle construction, including complete solutions for interior layouts.

SSC prides itself on being environmentally responsible, using sustainable materials wherever possible to benefit passengers, the economy and the environment, and so recognises the need for advanced materials offering superior performance and a unique combination of advantages for the rail industry globally.

Simultaneously, through Zotefoams’ unique material and SSC’s advanced technologies, an insulation system has been designed to meet the exacting requirements of railway industry standard EN45545. Its unique properties have been effectively demonstrated as SSC has since received recognition from the Watt d’Or awards – a prestigious award created by the Swiss Federal Office of Energy to acknowledge innovative Swiss companies setting new standards for solutions that unite energy and environment awareness – in the ‘Energy-Efficient Mobility’ category.

Find out more about Plastazote.

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