Case Study

This innovative project showcases how ARPRO CG enables extreme lightweighting and structural precision in thin-wall applications. In collaboration with the customer, JSP demonstrated how expanded polypropylene (EPP) can deliver high-performance, ultra-light components that meet demanding technical requirements.

Problem

Designing components with extremely thin walls—down to 2 mm—poses significant challenges in moulding. Traditional materials often lack the structural resilience or flexibility to fill thin cavities while maintaining impact resistance and form. The customer needed a solution that could deliver both ultra-lightweight construction and robust mechanical properties, without compromising on design complexity.

Solution

JSP supported the customer from concept through to production, using ARPRO CG to realise a breakthrough in thin-wall moulding. The material’s low density, durability, and mouldability enabled the development of a complex, high-performance component that met strict design, strength, and weight criteria. With expert guidance, advanced tooling, and process optimisation, JSP helped achieve consistent results and open the door to new lightweighting opportunities.

Key Features & Benefits

Ultra-Thin Wall Capability

• Successfully achieved 2 mm wall thickness using advanced moulding techniques.
• Demonstrated ARPRO CG’s ability to fill complex forms without compromising part integrity.

Extreme Lightweighting

• Delivered a sixfold weight reduction compared to traditional polyurethane (300g/l PU vs. 45g/l ARPRO CG).
• Supports fuel savings, material efficiency, and easier handling across applications.

Integrated Functional Design

• Enabled the combination of multiple design elements into one lightweight component.
• Reduced part count and assembly complexity, improving overall system efficiency.

Strong, Durable & Impact-Resistant

• Despite its low density and thin walls, the final part maintained excellent shock absorption.
• Suitable for demanding environments where strength and reliability are critical.

Want to explore lightweight, precision moulding for your next project? Contact JSP to learn more about what ARPRO CG can help you achieve.