Global
Performance Polymers

Cellasto® Services: More than just a material provider

When you work with our team, you have access to a large portfolio of materials with varying capabilities. This includes Cellasto®, a dynamic, resilient material available in a range of grades to suit multiple purposes and budgets.

A fully certified Tier 1 supplier for both industry and automotive customers, when you work with BASF Cellasto®, you get more than just materials. You gain a complete engineering package and the quick development, innovative testing and quality standards that come with it, including:

  • Simulation to predict product behavior
  • Up-to-date physical validation through various tests
  • Quality certifications, including environmental
Engineers Meeting in Technology Research Laboratory: Engineers, Scientists and Developers Gathered Around Illuminated Conference Table, Talking and Finding Solution Inspecting Industrial Engine Design

Why innovators choose Cellasto®

Cellasto® is a microcellular polyurethane elastomer that provides superior noise, vibration and harshness (NVH) reduction compared to rubber, plastic and other elastomers and is used in a wide range of applications and industries.

In automotive and independent aftermarket applications, this dynamic polyurethane foam’s high compressibility with low lateral expansion results in smaller, lightweight components.

The outstanding abrasion and environmental resistance of Cellasto® — including ozone and temperature — allow innovators to produce dynamic, durable components while maintaining a high level of design freedom. 

We offer this unique material in a range of grades to suit different budgets and purposes, from premium to economy. We even offer compact, non-foam material solutions for components, such as subframe mounts. This material still allows you to reap some of the benefits of a microcellular polyurethane, including improved NVH performance and abrasion resistance.

The cutting-edge technology and testing of Cellasto®

We currently have five testing sites worldwide with a broad range of load and frequency testing capabilities. Since prototypes are expensive, testing “on the bench” is key to avoiding costly mistakes. Our rigs can test the entire automotive system, from bumper to coil spring isolator.

Our machines are also capable of translating customer data into testing, such as the profile of road, force level, and accelerations, creating a quicker, more accurate loop of development. 

Static Testing

This initial test involves the slow deformation of the component through pressing, allowing OEM engineers to see the load-deflection curve (CLD). 

Drop Testing

From a drop height of up to 1 meter, we use drop testing to check the durability of the component. 

Hydropulser

This important durability and dynamic performance test is used to determine the lifetime of the automotive parts. This machine’s flexibility enables OEMs to define their own tests, including the shape and interruption of each movement. This test is appropriate if you need to determine the necessary load and amplitude in displacement as well as velocity.

This test is also ideal for electric cars or other vehicles with bumpers mounted to components other than the shock absorber, resulting in a dynamic movement rather than a linear one.

The hydropulser is particularly applicable to polyurethane testing, which counterbalances the unique properties of the material that make accelerated tests difficult to perform. Not only that, but our software is proprietary, which means we can upgrade or make changes quickly. 

As a result, parts for your electric cars and other vehicles containing our polyurethane foam can undergo testing that provides accurate results.

High-Frequency Test Rig

With a high frequency of 4000 Hz, this machine is ideal for testing the dynamic behavior of the bushings between the engine and the body when trying to reduce noise in the passenger cabin.

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Simulation capabilities

With more than 25 years of experience in application and theory, simulation is an integral part of our development process and is part of our digital competencies.

Our expertise is particularly strong in material mechanics and microcellular polyurethanes (MCU) modeling, as well as structural analysis through non-linear FEA (Finite Element Analysis).

Our technology, combined with the expertise of our CAE analysts, ensures that simulation serves to benefit the entire development process, resulting in Cellasto® products designed by BASF for high-performance applications.

Benefits of BASF Cellasto® Advanced Simulation Techniques

Using our research as well as leading software packages for non-linear FEA, BASF has developed advanced methodologies tailored to the specific needs of Cellasto® and its wide range of applications. 

Our simulation process accelerates the development phases by reducing the number of physical prototypes and amount of testing. In some cases, development cycles can even be skipped, enabling us to respond more quickly to our customers.

By using our FEA simulation methodologies in structural analysis, our CAE analysts can provide valuable information for Cellasto® product design, such as:

  • analysis of deformation behavior, including stability, contact and collision

  • load-deflection-characteristic and stiffness

  • stress/strain-analysis for assessment of local material loading and strength

  • reaction forces on assembled parts

Since proof of concept is possible without real prototypes, the BASF team can focus on product performance and quality from the start. Within virtual design loops, we can adopt and optimize product design to best fulfill your requirements. 

Our methodology even outperforms classical design methods due to its ability to provide insight that is not available by means of any other experimental technique, such as with physical tests that would be too large or too complex to be realized within the confines of a test lab. 

Quality Certificates

As leaders in green manufacturing, with more than 100 customers worldwide, adhering to strict safety, quality and environmental standards is a top priority. In addition to our long, successful track record in these areas, we have the following certifications:

IATF (International Automotive Task Force) 16949 Certification 

  • Requirement of Tier 1 Suppliers 

  • Ensures OEM quality is upheld

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ISO 14001 Certification 

  • Environmental focus

  • Includes CO2 emissions standards 

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RCMS Responsible Care Management System

  • Internal, broad BASF certification 

  • Ensures that we consistently produce environmentally conscious, safe products

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ISO 45001 Safety 

  • Occupational health and safety management system and use 

  • Provide a safe, healthy work environment through by preventing workplace injury and illness 

  • Take active steps to improving the company’s OH&S performance

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ISO 50001 Energy 

  • Improve and conserve energy use through an energy management system 

  • Create policies and use data to measure effectiveness for continuous improvement

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