Air Ducts - Thermoforming

TROCELLEN® Automotive as a strong partner for air ducts in the automotive industry

TROCELLEN® is one of the leading manufacturers of chemically and physically cross-linked polyolefin foams and combines its skills in the foam production with various converting capabilities. Together with our partners, we realize innovative applications and solutions that meet the requirements of the automotive industry. Our focus is on the development of thermoformed air ducts for the automotive industry. Our in-house developed twinsheet thermoforming process has proven itself in our products for years and has established itself on the market.

Our tailored solutions with sustainable customer value are the result of our longtime experience combined with our passion for automobiles.

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Optimized material xlpe foam

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Heat resistance up to 140°C

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Low burning rate (fmvss 302) < 100 mm/min

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Up to 65% weight saving

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Thermal insulation reducing energy losses

Twinsheet Thermoforming Air Ducts

The twinsheet thermoforming process using cross-linked PO foam was developed by TROCELLEN and has proven itself as a technically and commercially attractive alternative to the conventional blow molding process for the production of air ducts.

TROCELLEN’s distinguished know-how and in-depth customer support regarding optimal material choice and process parameters in combination with the company’s perfectly suited cross-linked PO foams have made TROCELLEN the preferred partner for manufacturers of serial twinsheet air ducts as well as car manufacturers. TROCELLEN represents innovation & development - Our products are constantly developed and improved in order to always offer our customers the maximum in quality and actuality.

Air duct

Advantages & Features of our Air Ducts

Due to the properties of the closed cell PO foam, the air ducts show excellent advantages compared to blow molded ducts:

  • Weight reduction – up to 65% lighter than solid air ducts
  • Thermal insulation improvement – reduction of energy loss
  • Acoustic absorption – up to 5dB less airflow noise
  • Easy assembly – high flexibility, good restoring behaviour
  • Sealing function – no squeak & rattle
  • No condensation – no bacteria
  • Easy prototyping – cost-efficient prototype tools and fast prototype production


Technical Drawing

Weight: HDPE vs. PO-foam

Weight: HDPE vs. PO-foam

Weight: PP vs. HDPE

Weight: PP vs. HDPE

Comparison Matrix – Thermoformed Soft PO-foam vs. Blow-molded HDPE Air Ducts

Comparison Matrix

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Individual Advice on Air Ducts

Not sure which materials to use? Our team of experts is there to help you. Together we will find the perfect solution for you. Please do not hesitate to contact us by phone.

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