Processing

ARPRO is a highly versatile material for moulding a wide variety of finished parts. Our customers enjoy a wider product portfolio, significantly reduced process costs, improved performance and advanced environmental benefits. We are constantly developing new material grades and moulding techniques, all in support of extending the range of ARPRO applications.

ARPRO can be moulded into large (up to 2m), complex, three dimensional shapes, by using temperature and pressure.

We provide design from concept to final validation utilising CAD, FEA and CFD. We also take an active role in optimising moulding plant layout helping you find improvements to increase efficiency and accuracy.

Moulding

ARPRO can be moulded into (almost) any shape. ARPRO is air conveyed through pipes into an aluminium mould which is then heated using steam (up to 4 bar). This causes the material to fuse and take the shape of the mould.

 

The combination of key material properties and processing techniques, such as insert moulding and new surface technologies, enable component functionality to be enhanced.

 

We provide extensive technical support which includes onsite support. We also work closely with press and tool (mould) makers.

Two dimensional diagram of a grey mould being filled with magenta ARPRO particles

Filling a mould cavity with ARPRO

Two dimensional diagram of a grey mould with a magenta moulded ARPRO part being ejected

A finished ARPRO part being ejected after steam fusion and cooling 

Fabrication

ARPRO can be used to fabricate custom packaging for heavy equipment, instruments, machinery and other industrial components, with parts being cut from moulded blocks. This is most applicable for limited series demand where construction of a tool would not be economical, or where items to be protected are subject to frequent change of design.

 

There are a number of cutting and adhesion techniques that can be used with ARPRO. Products are fabricated using skivers, saws, knives, water jets and suitable glue types.

 

 

A drill cutting sections out of a black ARPRO (expanded polypropylene) square

Ready, Set, Fabricate! 

A piece of black ARPRO (expanded polypropylene) being milled into a sample part

Milling ARPRO to create detailed, functional fabricated parts 

A fabricated part made by machine from ARPRO (expanded polypropylene)

Ta Dah! A finished fabricated part

Aesthetics

The aesthetics of ARPRO are incredibly versatile, with options ranging from colours, surface textures, surfaces and fabric coverings.

 

In addition, snap fit, tight tolerances enabling precision parts, living hinges, bespoke surfaces suitable for visible and tactile applications and the ability for complex shapes make ARPRO a highly versatile and visually pleasing material.

 

 

Grey ARPRO (expanded polypropylene) with a indented diamond surface, Dragon Fruit ARPRO with a bumpy dotted surface, Orange ARPRO with a cell structure surface and Lime ARPRO with a multi directional line surface.

Different colour and surface options 

Five rectangular boxes moulded from ARPRO (expanded polypropylene) colours - Blueberry, Dragon Fruit, Orange, Lemon and Lime

ARPRO Colour options 

Black ARPRO (expanded polypropylene) with a very thin hinge, called a living hinge

A living hinge 

Dragon Fruit ARPRO (expanded polypropylene) with wire mesh moulded into it

Moulding ARPRO with other materials