Foam and NVH

Tooling for foam and NVH parts

3D printed moulds for foam parts such as seating components, cushions, insulation and acoustic (NVH) parts. Ideal for development, pre-series and small series when aluminium tooling is too expensive or too slow.

Tooling for foam and NVH parts

Foam moulds

Whether a single mould for one part or a complete tool set, we deliver all required moulds within 2–3 weeks. The tools feature a smooth surface, a hardness of Shore 85D and the strength needed for foaming pressures of 10–15 psi. Stable temperature control and clean venting ensure even density distribution and repeatable part quality. The tool stays stable over many cycles: unlike conventional plastic tools there is no delamination or material fatigue.

NVH tooling (noise, vibration, harshness)

For acoustically effective parts such as insulation mats, wheel arch liners, engine bay and interior trim made of foam or fibre materials, we supply moulding and lamination tools with near-series process conditions. Acoustic concepts can be tested early under real conditions before investing in production tooling.

Typical applications

  • Seat cushions and backrests for automotive, rail, aerospace and motorcycles
  • Headrests, armrests, upholstery parts
  • Insulation and absorber parts, trim, acoustic components
  • Prototypes, pre-series and small series in flexible PU foam, integral foam and fibre composites

Why 3D printed tooling from Catalysis?

  • Lead time: 2–3 weeks after design approval instead of 3–6 months for aluminium
  • Cost: Around 50 % below aluminium, at the price level of Ureol
  • Tool life: Up to several thousand parts, far beyond Ureol and plastic 3D printing
  • Material: Natural sand material from foundry technology, dimensionally stable, isotropic, no plastic printing
  • One-stop: Design, 3D printing, finishing, quality inspection. No CAD needed on your side
Process

How a project runs

  1. 1Day 0

    Send data

    Tool data or just the part data. We design the tool if you have no CAD.

  2. 2Day 2–4

    Design approval

    You review the 3D design and approve it. Changes are quick at this stage.

  3. 3Day 5–15

    3D printing and finishing

    Sand printing, finishing and quality inspection.

  4. 4Day 14–21

    Delivery

    Shipped on a pallet, usually 2–3 weeks after approval. Base plate and connections on request.

Let's talk about your part

Planning a foam or NVH project? Send us part data and we will propose the right tool set.