Material data for simulating cross-linked materials – simple, practical, valuable
Do you process cross-linked materials such as thermosets or elastomers, for example in extrusion or transfer molding? If so, you know that product quality depends heavily on material behavior—and that is often difficult to predict. This is exactly where our project comes in.
Unlike thermoplastics, for which material characterization and simulation are now standard, there is often less expertise and fewer data sets available for cross-linked materials. Formulations are frequently more complex, which is why standard data sets cannot be relied upon. Our goal is to make material characterization simple and accessible in order to create a reliable material profile of your material with as few measurements as possible. This material map is validated during the ongoing process for the simulation program of your choice. To do this, we combine existing datasets with specific measurements of your material. The goal of the project is to establish a standardized process, which leads to cost-effective and reliable, meaningful simulations of your product. As a first step, your material is characterized and simulated at all relevant measurement points to establish the baseline against which comparisons are made. Subsequently, specific measurements are compared against existing standard datasets to determine which measurements have only a minor influence and which are indispensable for obtaining a reliable simulation. This enables you to further develop your products in the future with less measurement effort and to move efficiently from material to simulation without time-consuming iterations. The key question is: “How can you achieve a robust simulation with as few and as cost-effective measurements as possible?”
This project is specifically tailored to SMEs that do not have their own development department for the complex analysis of their materials. However, larger companies are also welcome to participate.
Duration: 24 months, planned start Q3-4/2026
Material cards: Minimum of 2 per company, more possible.
Costs: approx. 15,000 EUR/year (for two material cards, the price scales with the number of material cards to be created)
Solution and results
What do we offer?
Measurement & Analysis of Your Materials:
- Analysis Results – For daily use, even outside of simulation
- Material Profile – The key characteristics of your material, transferred into the simulation software
- Consulting on Material Optimization – If our analyses reveal potential for optimizing your material, we are happy to advise you on material development
Simulation of your material for optimized geometries and material properties (example: extrusion):
- Mold pressure curve and velocity profile – How can a homogeneous exit velocity be ensured with minimal pressure consumption?
- Temperature profile – Is the temperature correct to prevent unwanted cross-linking while simultaneously enabling good cross-linking?
- Additional process parameters – Do flow behavior, shear, and residence time match your material to produce a stable product?
- Consulting & support – from the initial idea to implementation in production
Your advantages
- Your entry into the world of simulation – Initial experience with simulation software, the foundation for more complex simulations of your components; your material profile enables precise predictions for future projects
- The developed process allows for future simulations with reduced measurement effort
- Insights from simulation reduce scrap and rework – through precise predictions of your material
- Faster development – because you know how your material behaves.
- Competitive advantage – through digital process optimization.
- No prior knowledge required – we handle the material characterization and, if necessary, the simulation technology as well.
What is measured?
We record all relevant parameters: flow behavior, curing, mechanical properties – and translate them into easy-to-use material maps for your simulation program.
What do you get?
Within this program, at least two material charts are determined for your products. The optimal balance between measurement effort and simulation accuracy is evaluated using coordinated test geometries. Based on this, a recommendation for material data determination and simulation is developed according to your individual resources for this topic.
Who is this interesting for?
For anyone working with cross-linked materials—whether in toolmaking, plastics processing, or product development. Particularly suitable for companies that want to produce more efficiently and avoid errors—regardless of whether you already use simulations for this or plan to do so in the future. Do you have a complex thermoplastic system? Of course, you are also welcome to participate in the project.
General conditions
An SKZ pioneer project is industry-funded contract research on current and technologically valuable topics. The participating industrial companies share the costs and jointly benefit from the practical research results. As no public funds are acquired, the findings are not made public and remain exclusively reserved for the participating companies. At the end of the project, you have a choice: keep your results exclusive – or opt for data exchange and benefit from the combined knowledge of all participants who have also chosen this option. The project is scheduled to start in Q3-4 2026 with a project duration of two years and a participation fee of approximately 15,000 EUR per year (for two material cards).
Interested?
Then contact us – we’ll show you how simple and effective material data can be. Your inquiry is non-binding. We’d be happy to advise you personally on the planned process and further details.
Did you know?
You can claim research services for tax purposes under the Research Allowance Act!
You can find out about the legal framework that applies to this on the website of the Federal Ministry of Finance. We would be happy to advise you on further funding opportunities.
Project parameters: Pioneering project
Duration: 24 months, planned start Q3-4/2026
Material cards: Minimum of 2 per company, more possible.
At the end of the project, each participant can decide whether to keep the material cards exclusively for themselves or to opt for data exchange and gain access to all material data from participants who have also chosen this option (with 8 project participants with two material cards who wish to exchange data, this corresponds to 16 material cards for these project participants).
Costs: approx. 15,000 EUR/year (for two material cards; the price scales with the number of material cards to be created)