Exciting applications in furniture design.
Perfect formability, best dimensional stability, high stability and impact strength are fascinating prospects for new products and new applications. We are talking about molded parts made of polyester fiber fleece – in short: molded fleece. It is sound absorbent, has a temperature-independent warm surface and a pleasant felt feel.
Pleasant haptics and 3D deformability
Positive material properties of nonwoven
The universal genius for room separation, storage, product presentation and more!
We permanently keep more than 1500 rolls of nonwovens of different colors and grammages for the needs and products of our customers.
The nonwoven mats are automatically cut from the respective roll according to the order.
The nonwoven fabric is heated in our special ovens to thereby activate the bico fibers. In the molded part, they ensure that the fibers are connected to each other.
The heated nonwoven forming mat is inserted into the opened mold and then cooled under pressure. This gives the molded part its final shape.
The CNC-controlled, precise cutting of the waterjet is performed by two robots working simultaneously. This enables a particularly resource-saving, economical approach. In addition, we offer other processing options.
If desired, fittings made of wood materials, plastics or metals, among others, can then be mounted and permanently bonded with the Becker Formvlies®.
Fascination molded fleece
3D deformation in perfection
Things to know about molded fleece
Concentrated know-how for your products.
If you are as enthusiastic about Becker Formvlies® as we are and would like to know even more details, you can find more information here.
Formability of molded nonwoven parts
How dimensionally stable are molded nonwoven parts?
Compared with shaped wood, shaped fleece is less stable. When used as a chair shell, for example, structural support is required. Other applications are possible “unsupported”.
To what thickness is the molded fleece compacted?
The compaction depends on the desired feel and strength and can be customized in each case. In most cases, a thickness of 6 mm is sufficient. If desired, the thickness can also vary within a component.
Why is the mixing ratio of the forming fleece variable?
The ratio of polyester fibers and the special polyester melting fibers is variable, because this controls the strength and feel of the nonwoven. The less melt fiber, the softer the molded part feels and the more flexible it is.
What are the deformation limits?
Becker Formvlies® allows strong three-dimensional deformation. However, the fleece only allows a certain stretching, which must be determined in each individual case.
How dimensionally stable is the pressed material when exposed to heat?
In normal use, e.g. in a residential environment, critical temperatures beyond the melting point of the fibers are not reached, so dimensional stability is maintained.
Shaped fleece and acoustics
How well does molded fleece absorb sound?
The absorption coefficient a indicates the proportion of the total incident sound that is absorbed. a = 0 means there is no absorption, all incident sound is reflected (example: glass surface). At a = 0.5, 50 percent of the sound energy is absorbed and 50 percent is reflected. At a = 1, the incident sound is completely absorbed, there is no more reflection (example: open window).
In laboratory measurements, Becker Formvlies® achieves a sound absorption coefficient of a = 0.55 in the frequency range 100 – 5000 Hz. It is thus assigned to sound absorber class D according to DIN EN ISO 11654.
In practical use, however, molded fleece achieves a far better degree of absorption.
Molded nonwoven: color options
Can the color tone be determined individually?
Yes, this is possible: on the one hand, fibers of different colors can be melanged together; on the other hand, for small batches, the fibers can also be dyed for uniform coloration (flock dyeing).
From which purchase quantity are individual colors possible?
With a minimum order quantity of 1,000 kg, almost any color can be produced after prior sampling and approval.
Can two colors be combined with each other?
Yes, they can be combined on top of each other, so that moldings on each side have a different color. Luminaires, for example, can be produced white inside and colored outside.
Do you offer standard colors?
Yes, we offer a selection of standard colors, which are composed of different grammages and Bico fiber content.
Design possibilities with shaped fleece
Can the molded fleece be pressed with logos?
Yes, logos are easy to emboss. Inserts are built into the molds for this purpose.
Can structures be produced on the surfaces of the molded nonwoven parts?
Yes: Structured inserts in the molds allow individual structures and attractive applications to be pressed in.
Can molded fleece be made directly with other fabrics as a finished surface?
Yes, the fleece can be laminated with other fabrics. In addition, different nonwovens can also be bonded together over a wide area (sandwich).
Is direct grouting with moldings made of wood possible?
No, because molded parts made of veneers are hot-pressed, while those made of fiber fleece are cold-pressed. Therefore, the two materials cannot be directly pressed together. However, the combination of wood and fleece can be realized by gluing.
Material properties molded nonwoven
What are the maximum dimensions that can be produced?
These depend on the sizes of the presses: We can produce workpieces of 2800 x 1400 mm, 2200 x 1280 mm and of 1950 x 1450 mm.
What about UV resistance?
Our molded nonwovens are rated 5 (= “Good”) according to DIN 53952. The best possible value is grade 8.
Does the molded nonwoven become electrostatically charged?
The ability to charge is very low in polyester fibers.
Can the material be assigned to a fire resistance class?
Molded fleece cannot be assigned to any fire resistance class as a general rule. Fire testing of the molded fleece component is always possible according to the required fire standard. If desired, fire resistance can be further increased by adding fire-retardant fibers.
Is the material safe for health in case of skin contact?
The Becker Formvlies® complies with the OEKO-TEX® Standard 100, whose requirements clearly exceed existing national laws. Molded nonwovens thus belong to Class 4, as do, for example, curtains, tablecloths and upholstered furniture covers.
Does molded fleece emit unpleasant odors?
No, the material is odorless.
How heavy are parts made of molded nonwoven?
The pressed molding has an average weight of 400g /m² to 4000g/m².
How resistant to aging is molded fleece?
Polyester is a very robust material and meets very high demands. Corresponding parts are also used in the automotive industry, for example, where several decades of service life are prescribed as a condition of use.
Can molded fleece also be used outdoors?
Depending on the synthetic fiber used, the nonwovens have better or poorer weather resistance. Fleece made of polyester fibers is conditionally suitable for outdoor use, if it is not exposed to constant weathering. To produce weather-resistant products, polyacrylic fibers are the most suitable.
Molded fleece and sustainability / environmental protection
Where does Becker get the nonwovens from?
The nonwovens we use all come from European production.
How does disposal work at the end of the life cycle of nonwoven products?
Formed parts made of nonwoven can be shredded at the end of their use, remelted and spun into new fibers.
Can recycled material also be used?
Of course: nonwovens made from 100% recycled fibers can be used on request.
Can molded parts also be made from natural fiber nonwovens?
Yes: molded nonwoven products can be made from natural fibers such as hemp, kenaf or flax and can even be composted at the end of their life cycle.