Sports gear brand required a knee protector foam liner meeting EN1621-1 Level 2 (peak force <35kN) while maintaining flexibility at -20°C for all-season riding conditions.
Selected low-temperature modified PU foam compound. Optimized cell structure with density gradient — harder outer zone 120 kg/m³ for initial impact, softer inner zone 60 kg/m³ for comfort.
EN1621-1 Level 2 certified. Peak force 28.4kN at room temperature, 31.8kN at -20°C. 40% weight reduction versus previous EVA foam design.
DFM Analysis: Multi-zone mold temperature control (inner 35°C / outer 55°C) achieved density gradient in single shot — eliminated need for bonded dual-layer construction.
Our engineers work from your CAD drawings before any tooling begins — identifying potential failure modes, proposing material alternatives, and validating gate/cooling layouts digitally. This eliminates costly mold revision cycles.
Physical test results from production samples — available with every shipment on request.
| Test | EN1621-1 Level 2 Requirement | Result |
|---|---|---|
| Peak Force (20°C) | ≤ 35kN | 28.4 kN |
| Peak Force (-20°C) | ≤ 35kN | 31.8 kN |
| Weight vs. EVA | Target -30% | -40% achieved |
| Flexibility at -20°C | No cracking | PASS |
Share your drawings, quantity and material requirements. Our team performs a complimentary DFM review before quoting.
