Extrusion dies represent one of the most critical elements in the foam production line of physically expanded, non-cross-linked closed-cell polymer foams. FAP stands out for its high precision in the design and manufacturing of extrusion dies, ensuring optimal performance and minimizing production defects.
Our dies are specially engineered to work with Isobutane, n-Butane, propane/butane, CO2, and nitrogen as physical blowing agents, guaranteeing consistent foam structure, superior cell uniformity, and enhanced product quality. This versatility in gas compatibility not only improves production efficiency but also contributes to more sustainable and cost-effective solutions.
FAP's extrusion dies are designed to optimize the use of each blowing agent, allowing manufacturers to customize the foam characteristics according to the specific requirements of the application.
Accurate design of an extrusion die is essential to avoid issues such as:
Pressure loss below 1.6 MPa, causing premature phase transitions of dissolved gas and compromising the quality of the expanded foam produced.
Friction and surface tension from inadequate materials and processing, risking polymer degradation and flammability.
Thermal imbalances due to ineffective thermal conductivity management, negatively impacting the expansion process.
FAP offers different types of extrusion dies (heads), tailored for the production of physically foamed polyethylene (PE), polypropylene (PP), and polystyrene (PS), meeting density requirements ranging from 15 kg/m3 to 400 kg/m3.
FAP’s foam extrusion dies (heads) for sheets manage different thicknesses with varying pressures to achieve excellent materials in terms of density, cell uniformity, and other technical characteristics.
Additionally, FAP extrusion dies (heads), with their exclusive design, allow an average gas savings of 15%.
FAP’s exclusive and original extrusion die design for thin and normal thicknesses ensures excellent material control and perfect distribution inside before exiting.
Technical Data:
🔹 Sheet foam thickness: 0.3 mm - 5 mm
🔹 Sheet foam width: 1000 mm - 3000 mm
🔹 Pneumatic pressure regulation system
🔹 Titanium nitride coating
🔹 Advanced anti-adhesive treatment
🔹 Quick-release system
Advantages:
🔹 Uniform pressure distribution to reduce “wave” effects, even on ultra-thin foam materials (0.5-1 mm), minimizing breakage during expansion.
🔹 High-quality expanded materials with homogeneous cells.
🔹 Ultra-low density materials produced with intact cells and expanded polymer, avoiding collapse risks.
FAP’s exclusive and original extrusion die design for normal and high thicknesses, with a special smoothing ring, ensures excellent control and high quality in producing high-thickness expanded materials.
Technical Data:
🔹 Sheet foam thickness: 6 mm - 30 mm
🔹 Sheet foam width: 800 mm - 1550 mm
🔹 Pneumatic pressure regulation system
🔹 Titanium nitride-coated components
🔹 Advanced anti-adhesive treatment, reducing polymer friction
🔹 Adjustable pneumatic system
🔹 Quick-release system for fast changes
Advantages:
🔹 Flat, wave-free expanded materials of normal and high thickness.
🔹 High-quality expanded materials with homogeneous cells.
🔹 Exclusive design to increase thickness up to 3 mm.
Technical Data:
🔹 External diameter: 12 mm - 200 mm
🔹 One or two flow systems
🔹 Automatic melt flow changeover without interruptions
🔹 Independent oil temperature control for each die
🔹 Advanced anti-adhesive treatment
Advantages:
🔹 High-quality expanded profiles, pipes, and cords with homogeneous cells.
🔹 Exclusive design enabling wall thicknesses up to 25-30 mm for insulating pipes.
🔹 Complex expanded polyethylene profile manufacturing.
FAP Srl is a member of AMAPLAST Italian Plastics and Rubber processing machinery and
moulds manufacturers’ association.
