IKV: Research for Practical Application Innovations in TPS Foam, Lightweight Construction with UD Tapes, and Viscosity Control

Whether it’s flexible foam films made from starch, lightweight construction using UD tapes, or AI-based viscosity control for recycled materials—IKV Aachen is charting new paths for practical applications. How can sensitive biopolymers be processed reliably? What cost-saving potential do bionic reinforcing inserts offer? And how can viscosity be balanced during the ongoing compounding process?

Foam Extrusion of Starch-Based Thermal Paste

Industrial foam films, such as those used for packaging or impact sound insulation, consist primarily of polymers derived from fossil-based raw materials, which are often thermally recycled after a single use. One way to make extruded foam products more sustainable is to use renewable raw materials, such as starch. However, the production of flexible foam films from thermoplastic starch (TPS) has been virtually impossible to date due to TPS’s low melt strength and narrow processing window. To expand the process window for the production of low-density flexible starch foam films, researchers at the IKV, as part of a project funded by the Federal Ministry of Food, Agriculture, and Home Affairs (BMELH), investigated the use of blowing agent mixtures based on CO₂.