Possibilities, rediscovered by us:<br>
Exciting Formfleece
Possibilities, rediscovered by us:
Exciting Formfleece

Formfleece

An innovative material for innovative ideas

Perfect deformability, best dimensional stability, high stability and impact resistance are fascinating perspectives for new products and new applications. We are talking about moulded parts made of polyester fibre fleece. It is sound-absorbing, has a warm surface that is independent of the room temperature,

and a pleasant felt-like touch. The use of Formfleece for modern product design offers fascinating possibilities for creative innovation. Becker has developed specific moulding techniques for 3D deformation and initiated a new trend.

Deformation steps in the processing of Formfleece

How we create a Formfleece object.

Materialeigenschaften

Material properties

Formfleece is available in many colours and allows to make three-dimensional deformations. Different fibre mixtures make it possible to define the strength and the textile surface feel of the moulded parts as desired. Combinations with other materials can be produced and coins are also possible. Even rich shades can be obtained by dyeing.

Schallabsorption

Sound absorption

The open fibre structure is sound-absorbing. During laboratory measurements Formfleece reaches a sound absorption of aw = 0.55 in the frequency range of 100 - 5000 Hz. According to the standard DIN EN ISO 11654, it is assigned to the sound absorption class D. In practice, Formfleece achieves a far better degree of absorption.

Werkzeuge

Tools

For the production of Formfleece we need a form that we develop and build according to your requirements. The costs of such a tool are in the range of a pressing tool for moulded wood.

Becker know-how

Answers to your questions

Material deformability

How dimensionally stable are moulded formfleece parts?

Formfleece is not as dimensionally stable as molded wood. If formfleece is used for chair shells, an additional supporting structure must be provided. No support is required for other applications.

To which thickness is formfleece compressed?

The respective compression depends on the feel and stability desired and can be tailored to customer requirements. Mostly, a thickness of 6 mm is sufficient. It is possible to vary the thickness within one part.

Why is the mixing ratio of formfleece variable?

The mixing ratio of polyester fibers and the special thermal bonding polyester fibers is variable, since the ratio determines the firmness and feel of the product. The fewer thermal bonding fibers, the softer the molded part feels and the more flexible it is.

What deforming limits are there?

Formfleece allows strong three-dimensional deformation. The fleece can only be expanded up to a certain degree, which must be identified for every individual case.

How dimensionally stable is the compressed material when heat is applied?

Under normal conditions in a residential environment, critical temperatures above the melting point of the fibers are not reached.

Sound-absorbing properties

How well does BECKER formfleece absorb sound?

The absorption coefficient a specifies how large the absorbed proportion of the total incident sound is. a = 0 means that there is no absorption; the entire incident sound is reflected (example: glass surface). If a = 0.5, 50 percent of the acoustic energy is absorbed, and 50 percent is reflected. If a = 1, the complete incident sound is absorbed, which means that there is no reflection (example: open window). In laboratory measurements, BECKER formfleece achieves a sound absorption coefficient of aw = 0.55 in a frequency range from 100 – 5,000 Hz. According to the standard DIN EN ISO 11654, it belongs to sound absorption class D. In practice, formfleece achieves a much better absorption coefficient.

Colouring options

Can the colour be customized?

Yes, that is possible. Different-coloured fibers can be blended. For small batches, the flocks can also be dyed. Uniform colouring is possible.

How large does the purchase quantity have to be so that customized colours can be realized?

Can two colours be combined with each other?

How large does the purchase quantity have to be so that customized colours can be realized?

From a minimum purchase quantity of 1.000 kg, nearly every colour can be produced. After a colour matching process, production is approved.

Can two colours be combined with each other?

Yes, they can be combined by placing them on top of each other so that each side of a molded part has a different colour. Lamps, for example, can be white inside and coloured on the outside.

Design possibilities

Can logos be pressed into the formfleece?

Logos are easy to emboss. To do this, inserts are built into the molds.

Can formfleece be manufactured directly with diverse fabrics as finished surfaces?

The fleece can be laminated with other fabrics. Different fleece fabrics can be glued to each other (sandwich).

Can formfleece be manufactured directly with diverse fabrics as finished surfaces?

The fleece can be laminated with other fabrics. Different fleece fabrics can be glued to each other (sandwich).

Is it possible to compress formfleece directly together with molded wood parts?

Molded parts from laminates are compressed in hot processes, fiber fleece parts in cold processes. Therefore, the two materials cannot be compressed with each other directly. They can be combined after compression by sticking them together.

Material properties

What are the maximum dimensions are produced?

This depends on the pressing sizes. Workpieces of 2400 x 950 mm or 1950 x 1450 mm can be produced. 

How does the material react to UV radiation?

According to DIN 53952, it has a grade 5 UV resistance, which is equivalent to the classification »Good«. The best value is a grade 8.

Does BECKER formfleece charge itself up electrostatically?

Polyester fibers show only little electrostatic charging.

Can the material be assigned to a fire resistance class?

Formfleece cannot be assigned to a general fire resistance class. A fire testing of the formfleece component is always possible according to the required fire safety norm. The fire resistance can be further increased adding flame-retardant fibres.

Is skin contact with formfleece harmless to one's health?

Formfleece meets OEKO-TEX® standard 100, whose requirements are much stricter than the provisions of existing national laws. Formfleece belongs to class 4, the same as curtains, table cloths, covers of upholstered furniture, etc.

Does it have an unpleasant smell?

No, the material is odorless.

How much does BECKER formfleece weigh?

Pressed molded parts weigh 2,300 g/m² on average.

How resistant is formfleece to ageing?

Polyester is an extremely robust material and meets very high requirements, for example, the requirements of the car industry, where several years of life are stipulated.

Can formfleece be used for outdoor applications?

Depending on the synthetic fiber used, the fleece is more or less weather resistant. Fleece made of polyester fibers are partially suitable provided they are not exposed to continuous weathering, however to produce a weather-resistant material, acrylic fibers are most suitable to use.