August 24, 2025 • 15 mins
What if seals could be created directly on your part—no cutting, no insertion, no seams? In this episode of Adhesion Matters, we dive into Henkel’s Sonderhoff Formed-in-Place Foam Gasket (FIPFG) technology, a system that applies liquid foam directly onto components where it cures into seamless, precise, and highly resilient gaskets. We explore how polyurethane systems like FERMAPOR K31 and silicone foams like FERMASIL are transforming sealing in industries ranging from electronics enclosures and automotive modules to household appliances and e-mobility charging stations.
Beyond technical performance, we highlight how FIPFG advances sustainability—eliminating waste from punched gaskets, reducing energy with room-temperature curing, and offering long service life through exceptional compression recovery. We also examine the role of automation and robotics in enabling consistent, scalable application.
Whether you’re an engineer, product designer, or operations manager, this episode shows why the future of gasketing is being shaped—in place.
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Transcript
Episode Transcript
Available transcripts are automatically generated. Complete accuracy is not guaranteed.
Elena Bondwell (00:00):
You know that really satisfying sound, that
sort of solid thud when youclose a car door?
Lucas Adheron (00:04):
Yeah, or like when your dishwasher's running
and it's just humming awayquietly.
Elena Bondwell (00:07):
Exactly.
We kind of just expect thatreliability, right?
But there's some seriousengineering going on behind the
scenes, stuff we don't usuallysee.
Lucas Adheron (00:15):
A lot of hidden tech.
Elena Bondwell (00:16):
Right.
Okay, let's unpack this then.
Today we're doing a deep diveinto, well, advanced sealing
technology, specificallysomething called formed-in-place
foam gaskets.
FIPFG
Lucas Adheron (00:30):
for short.
FIPFG, yeah.
Elena Bondwell (00:31):
It might sound a bit, you know, technical, but
honestly, this stuff isimpacting everything.
Your car, appliances in yourkitchen, even green energy
setups.
Lucas Adheron (00:40):
And for this dive, yeah, we've gathered quite
a bit of insight from Henkel.
They're real pioneers withtheir Sonderhof FIPFG
technology.
Elena Bondwell (00:47):
Okay.
Lucas Adheron (00:47):
We're looking at...
New material propertiesdesigned for car parts, how it
applies to sustainablemanufacturing, which is huge
right now, and even somereal-world examples like in
power distribution systems.
Elena Bondwell (00:59):
So what's the mission here?
Lucas Adheron (01:01):
Well, the mission is really to figure out how
this approach, this 50FG, ischanging the game.
how it's redefining precision,boosting efficiency, and
surprisingly, sustainability inmanufacturing.
Elena Bondwell (01:12):
OK, so if you've ever wondered about that
invisible tech that keeps yourgadgets working or your car
sealed up tight.
Lucas Adheron (01:19):
Or how manufacturers are actually
managing to cut costs and theircarbon footprint at the same
time.
Elena Bondwell (01:24):
Then yeah, you're probably in for some real
aha moments today.
We're going to see how a tinycomponent can make a massive
difference.
It's quite fascinating,actually.
So before 50FG really took off,what was the Standard.
The old way of sealing things.
Lucas Adheron (01:40):
Right.
The traditional methods.
Mostly you're looking atpre-cut seals, like pieces
punched out of sheets ofmaterial, maybe EPDM, TPE, that
kind of thing.
Elena Bondwell (01:48):
Okay.
So like pre-formed shapes.
Lucas Adheron (01:49):
Exactly.
And then picture this.
Someone on the assembly lineliterally peeling off a backing
and sticking the seal into placeinside an appliance maybe or a
car door frame.
Elena Bondwell (02:00):
That sounds fiddly.
And slow?
Lucas Adheron (02:03):
It was.
And, you know, while thoseseals did a job, they had
weaknesses built right in.
Think about where two pieces ofa pre-cut gasket meet or where
the ends join up.
Those seams.
Elena Bondwell (02:14):
Potential leak points?
Lucas Adheron (02:15):
Absolutely.
Weak spots for water, for dust,even for noise and vibrations
to get through.
And the manual part, applyingthem by hand, it's not just
slow, it's inconsistent, proneto errors.
Elena Bondwell (02:29):
Especially when you're trying to make...
Thousands of units a day.
Lucas Adheron (02:32):
Right, exactly.
As production scales up andproducts get more complex, that
old method just struggles.
It can lead to a rework,warranty issues, basically a
less reliable product for theend user.
Elena Bondwell (02:43):
Yeah, I can see that.
If you're a manufacturer tryingto grow or just someone buying,
say, a dishwasher, you want itto last.
You don't want leaks caused bya tiny gap in a seal.
Lucas Adheron (02:52):
Those small inconsistencies become big
problems.
Costs go up, quality suffers.
Elena Bondwell (02:57):
Okay, so the old way had issues.
What was the Burke throughthen?
What makes Henkel's IPFG sodifferent, so revolutionary?
Lucas Adheron (03:04):
It's a completely different philosophy, really.
A radical shift.
Instead of taking a pre-madeseal and trying to fit it
perfectly.
Elena Bondwell (03:10):
Which is hard.
Lucas Adheron (03:11):
Which is very hard, yeah.
FIPFG technology forms thegasket directly onto the part
itself.
Elena Bondwell (03:17):
Forms it?
How?
Lucas Adheron (03:18):
Imagine a robotic arm.
moving with incredible speedand accuracy.
It dispenses a liquid foamprecisely along the groove or
surface where the seal needs tobe.
Elena Bondwell (03:28):
Like 3D printing a seal?
Lucas Adheron (03:30):
Kind of, yeah.
It molds itself instantly toevery curve, every contour, and
it creates this seamless,perfectly shaped seal made of
elastomer right there inseconds.
Elena Bondwell (03:41):
Wow.
Okay.
Seamless is the key word there,I guess.
No joins, no gaps.
Lucas Adheron (03:44):
Exactly.
That's the magic.
How does it work?
Well, it's usually atwo-component system.
Polyurethane, maybe silicone.
These two liquids mix right atthe dispensing head.
Elena Bondwell (03:54):
A sophisticated mixing head, I imagine.
Lucas Adheron (03:56):
Oh, yeah.
Typically CNC-controlled,computer numerical control.
So think super precise,computer-guided application.
This mixed foam is dispensed,and then it just cures right
there in place.
It becomes a solid, flexibleseal.
Elena Bondwell (04:07):
And that formed-in-place part is what
eliminates those weak points youmentioned.
Lucas Adheron (04:11):
Precisely.
No seams, no joins means nobuilt-in weak spots.
You get a continuous,uninterrupted barrier.
And the precision is amazing.
We're often talking tolerancesdown to plus or minus 0.1
millimeters.
Elena Bondwell (04:24):
That's tiny.
Way more accurate than stickingsomething on by hand.
Lucas Adheron (04:27):
Oh, absolutely.
You just can't get thatconsistency manually.
Elena Bondwell (04:31):
So for you, the person using the final product,
what does that mean?
It means things are sealedreally, really well, like zero
gap sealing, they call it.
Lucas Adheron (04:40):
Right.
And high sitting resilience,which means it bounces back
after being compressed.
Elena Bondwell (04:44):
And this tech can hit standards like IP68
protection.
Lucas Adheron (04:48):
It can, yeah.
Elena Bondwell (04:49):
Okay, for anyone not up on their IP ratings,
IP68 is basically top-tierprotection against dust and
water, like serious waterresistance, even immersion.
Lucas Adheron (04:58):
It means your electronics, car parts,
appliances, they're properlysealed against the elements,
protected.
It gives you peace of mind.
Elena Bondwell (05:05):
But it's not just how the seal is made, is
it?
The material itself has to beright.
A perfect application won'thelp if the foam isn't up to the
job.
Lucas Adheron (05:12):
Absolutely crucial.
The material is the heart ofthe seal.
And Henkel has options,tailored solutions.
Let's talk polyurethane.
They're Sonderhof Vermipore K31range, for instance.
Okay.
These are two-component PUfoams, and they're engineered
for incredible resilience.
Like, they have thisnear-perfect resetting ability,
often over 95%.
95%
Elena Bondwell (05:33):
reset.
What does that mean inpractice?
Lucas Adheron (05:36):
It means if you compress it like closing a door
or a lid, it springs back almostperfectly to its original shape
time after time.
Think of it as a dishwasherdoor seal.
You open and close itconstantly.
If it doesn't reset well, itdevelops gaps, leaks.
Elena Bondwell (05:49):
Ah.
Ah, okay.
So high reset means it keepssealing properly for longer.
Lucas Adheron (05:52):
Exactly.
It's key for longevity.
Plus, these PU foams are reallystable against hydrolysis.
They don't break down easilywith water exposure and
temperature stable too.
They meet tough automotivestandards like DBL 5452, meaning
they perform reliably in heat,cold, vibration.
Perfect for those demandingIP68 seals.
Elena Bondwell (06:11):
Okay.
So polyurethane sounds greatfor resilience for common but
tough conditions.
What if you need something evenmore extreme?
Lucas Adheron (06:18):
Good question.
Because yeah, it Different jobsneed different tools, different
materials.
Right.
And that's where silicone foamscome in, like Henkel's
Sonderhof Vermisil range.
Elena Bondwell (06:26):
Silicone, right.
Usually good with temperatures.
Lucas Adheron (06:28):
Extremely good.
Vermisil, for example, canhandle a huge temperature range.
We're talking from minus 60degrees Celsius, like Arctic
cold, up to plus 180 C.
And it can even take shortbursts up to 350 degrees
Celsius.
Elena Bondwell (06:42):
Wow.
Okay.
That's serious heat.
Lucas Adheron (06:45):
It is.
And it's typically a closedcell foam.
Imagine tiny bubbles inside,but none are connected.
That makes it exceptionallygood at keeping out water and
gases.
Very weather resistant,chemical resistant too.
Ideal for really toughindustrial uses, outdoor
electrical boxes, chemicalequipment, things like that.
Elena Bondwell (07:02):
So it's not one size fits all.
It's about matching thematerial PU or silicone or
specific grades to the exactneeds of the application.
Lucas Adheron (07:10):
Precisely.
Whether you need that extremetemperature range or the
incredible bounce backresilience for constant use.
It's about getting the perfecttailored seal for the job, like
bespoke tailoring, but forgaskets.
Elena Bondwell (07:21):
Okay, so the seals themselves are incredibly
precise, durable, tailored.
That's great for the product.
But what about themanufacturers?
How does FIPFG change things onthe factory floor?
Does it speed things up, cutcosts?
Lucas Adheron (07:34):
Oh, absolutely.
It's a massive efficiencybooster.
These FIPFG systems, they useadvanced dosing machines.
Henkel makes specialized onesunder the Sonderhoff brand, and
they work incredibly fast andconsistently.
Elena Bondwell (07:45):
Robots doing the work.
Lucas Adheron (07:46):
Often, yeah.
Stationary setups or roboticarms.
It means the application isquick, it's precise every single
time, totally repeatable.
Automation takes out the humanerror, speeds up the whole line.
Elena Bondwell (07:57):
Can you give an example?
Like where has this made a bigdifference?
Lucas Adheron (08:00):
Sure.
A great case study is in theautomotive world, specifically
ceiling car door modules.
Modern car doors are stuffedwith electronics, right?
Window motors, locks, speakers.
Elena Bondwell (08:10):
Yeah, complex bits.
Lucas Adheron (08:11):
Very.
And all that needs protectionfrom rain, dust, vibration.
So the FIPFG solution uses aspecific two-component PU foam,
again from that SonderhoffFermipore K31 family, and it's
applied fully automatically byrobot.
Elena Bondwell (08:24):
Okay.
What's the big win there?
Lucas Adheron (08:25):
Well, a couple of things.
This This particular foam has areally neat combination.
A decent pot life, meaning itstays liquid and workable for a
short while after mixing anddispensing.
Elena Bondwell (08:35):
Giving the robot time to finish the pattern.
Lucas Adheron (08:37):
Exactly.
But then it cures really fast,so the door module can be
handled and moved down theassembly line very quickly.
Shorter cycle times.
No need for big racks of partswaiting to cure.
Elena Bondwell (08:49):
Ah, saving space and time.
Lucas Adheron (08:50):
Definitely.
And another thing, thisspecific foam has a slightly
lower density, about 5% lower.
Sounds small, but it means lessmaterial used per door, which
saves money and makes the doorcomponent a tiny bit lighter.
Elena Bondwell (09:02):
Every gram counts in automotive, right?
For fuel efficiency.
Lucas Adheron (09:06):
Absolutely.
Plus, requires less force toinstall the module, which makes
assembly easier and helps ensurea tight seal, even if there are
slight variations in the parts.
Elena Bondwell (09:14):
That sounds like a win-win-win.
Faster, cheaper, lighter,better seal.
Lucas Adheron (09:18):
Pretty much.
But it's not just cars.
Elena Bondwell (09:20):
Right.
You mentioned powerdistribution.
Lucas Adheron (09:22):
Yeah.
Another great example.
We saw a case where a companymaking electrical enclosures
like cabinets for circuitbreakers and stuff.
They were using those manualpeel-and-stick foam tapes.
It was slow, error-prone,really a bottleneck as their
orders increased.
They needed something faster,better quality, and ideally
something that wouldn't increasetheir costs, maybe even lower
(09:44):
them.
Elena Bondwell (09:44):
Pay classic manufacturing challenge.
Lucas Adheron (09:46):
Yeah, right.
So the solution was putting inan automated FPFG dosing system,
again using FermiPort K31, andthe results were, frankly,
amazing.
Elena Bondwell (09:55):
How amazing.
Lucas Adheron (09:56):
They reported a cost reduction of more than 30%.
30%.
Elena Bondwell (09:58):
That's huge.
Lucas Adheron (10:00):
Huge.
Plus, quality went way up.
Consistency was perfect.
Defects basically disappeared.
And because it's on-demandapplication, they had more
flexibility.
They could produce more faster.
It completely changed theiroperation, turned that
bottleneck into a realadvantage.
Elena Bondwell (10:16):
Okay, a 30% cost cut is seriously impressive.
But isn't the initialinvestment in these automated
robotic systems pretty high?
How do companies, especiallysmaller ones, justify that?
Lucas Adheron (10:26):
That's a fair point.
There is an upfront investment,no doubt, but the return on
investment, the ROI, is oftensurprisingly fast.
Elena Bondwell (10:33):
How so?
Lucas Adheron (10:33):
Well, think about it.
You eliminate the manual laborcost for applying seals.
You drastically cut materialwaste.
No offcuts.
Production speed shoots up.
Quality improves dramatically,meaning fewer rejects, fewer
warranty claims down the road.
Elena Bondwell (10:47):
Okay, so the savings start adding up quickly
across
Lucas Adheron (10:50):
different areas.
Exactly.
It compounds.
So for many manufacturers, it'snot just seen as a cost, but as
a strategic investment.
It makes them more competitive,lets them meet higher quality
demands, and kind offuture-proofs their production.
Elena Bondwell (11:03):
Makes sense.
It's an investment inefficiency and quality.
And you mentionedsustainability earlier, too.
How does 5PFG fit into thatpicture?
Because better products arewhat?
One thing, but making themresponsibly is another.
Lucas Adheron (11:15):
It really ties in strongly.
And it raises that importantquestion about longevity, right?
A high quality product thatlasts longer is inherently more
sustainable, less replacement,less waste.
Right.
And remember that high settingresilience of the Fermipore K31
foams, that ability to recoverup to 95%.
It means housings or enclosuressealed with it can often be
(11:36):
opened and reclosed withoutdamaging the seal for repairs,
for maintenance.
Elena Bondwell (11:40):
Ah, so it supports repairability.
Lucas Adheron (11:42):
Yes.
Think about, say, the dirt trapin your dishwasher.
You need to take it out andclean it regularly.
A good FIPFG seal there meansit stays watertight even after
being opened and closed dozens,hundreds of times.
Or photovoltaic inverters theboxes that manage solar panel
output.
Elena Bondwell (11:59):
Yeah.
Lucas Adheron (12:00):
Being able to easily open them for maintenance
without wrecking the sealextends their service life,
keeps those solar panels workingefficiently for longer.
That's direct sustainability inaction.
Elena Bondwell (12:11):
That's a really good point.
Durability throughrepairability.
What about waste duringmanufacturing itself?
You mentioned less material.
Lucas Adheron (12:18):
Right.
Big difference there.
With FIPFG, you dispenseexactly the amount of foam
needed right where it's needed.
No punching shapes out ofsheets, no leftover scrap
materials, zero punching waste.
You use 100% of the foam.
Elena Bondwell (12:30):
Okay.
Lucas Adheron (12:30):
And we already mentioned the lower density
means less raw materialconsumption overall, better CO2
balance, lighter parts.
It all adds up.
Elena Bondwell (12:37):
And the process itself, any green benefits
there?
Lucas Adheron (12:40):
Definitely.
These two-component foam No
Elena Bondwell (12:43):
big ovens needed.
Lucas Adheron (12:44):
Exactly.
No need for massive,energy-hungry tempering ovens to
cure the seals.
That saves huge amounts ofenergy and upfront investment.
Also, the dynamic misting headsthey use are designed to
minimize waste compared to olderstatic mixing tubes that needed
frequent replacing.
Elena Bondwell (13:01):
How are they cleaned?
Lucas Adheron (13:02):
Ecologically, actually.
Yeah.
Typically with high-pressurewater, not harsh chemical
solvents, which is much betterfor the environment and worker
safety.
Elena Bondwell (13:11):
Water.
Does that use a lot of waterthen?
Lucas Adheron (13:13):
Well, this is pretty cool.
Henkel's even developed rinsingwater recycling systems.
They filter and purify thewater used for cleaning the
mixing head so it can be reused.
Cuts That's
Elena Bondwell (13:24):
clever.
Closing the loop?
Lucas Adheron (13:26):
Yeah.
And digitalization plays arole, too.
Sensors in the mixing headconstantly monitor the process
to ensure quality.
They can also predict whenparts might need maintenance,
avoiding unexpected downtime.
Elena Bondwell (13:38):
Predictive maintenance.
Lucas Adheron (13:39):
Right.
And things like online supportfor troubleshooting can reduce
the need for technicians totravel, cutting CO2 emissions.
The systems can even trackmaterial consumption and
calculate the associated CO2footprint.
Elena Bondwell (13:50):
Wow.
So you get real-time data onthe environmental impact.
Lucas Adheron (13:54):
Yeah.
It's bringing smart, greenmanufacturing principles right
into the sealing process.
Elena Bondwell (13:58):
It really shows how advanced tech and
sustainability can go hand inhand.
It's not always a trade-off.
Lucas Adheron (14:04):
Not at all.
In this case, the advanced techenables better sustainability.
Elena Bondwell (14:08):
So wrapping this up, then, from keeping our car
doors tightly sealed againstwind and rain to making sure a
solar inverter can be easilyrepaired to last longer, this
deep dive really shows howformed in place foam gaskets
are, this sort of silent, hiddenpowerhouse, driving efficiency,
saving costs, and boostingsustainability in so many
(14:30):
different industries.
It's impressive stuff.
Lucas Adheron (14:31):
It really is.
And if you connect into thebigger picture, it's just a
fantastic example of howmaterial science the actual foam
chemistry and automation, therobotic application are coming
together.
Elena Bondwell (14:42):
It's like converging.
Lucas Adheron (14:43):
Converging to not just make products perform
better and last longer, but alsoto genuinely reduce our
environmental impact across thewhole life cycle, from making it
to using it to repairing it.
Elena Bondwell (14:53):
It really challenges that old idea that
high tech automatically means ahigher ecological price tag.
Lucas Adheron (15:00):
Exactly.
It proves innovation canactually be the key to a more
sustainable approach.
Elena Bondwell (15:04):
Okay, so here's a final thought to leave you
with.
As you go about your Maybenotice those seals.
Or maybe just think about allthe other unseen bits of
technology, the hidden gasketsand components quietly doing
their jobs everywhere.
How many other invisibleinnovations like FitPFG are out
there, quietly revolutionizingindustries, making things more
(15:25):
efficient, more sustainable,right under our noses?
Lucas Adheron (15:28):
Makes you wonder what the next hidden game
changer will be.
Elena Bondwell (15:30):
It really does.
You know that really satisfying sound, that
sort of solid thud when youclose a car door?
Lucas Adheron (00:04):
Yeah, or like when your dishwasher's running
and it's just humming awayquietly.
Elena Bondwell (00:07):
Exactly.
We kind of just expect thatreliability, right?
But there's some seriousengineering going on behind the
scenes, stuff we don't usuallysee.
Lucas Adheron (00:15):
A lot of hidden tech.
Elena Bondwell (00:16):
Right.
Okay, let's unpack this then.
Today we're doing a deep diveinto, well, advanced sealing
technology, specificallysomething called formed-in-place
foam gaskets.
FIPFG
Lucas Adheron (00:30):
for short.
FIPFG, yeah.
Elena Bondwell (00:31):
It might sound a bit, you know, technical, but
honestly, this stuff isimpacting everything.
Your car, appliances in yourkitchen, even green energy
setups.
Lucas Adheron (00:40):
And for this dive, yeah, we've gathered quite
a bit of insight from Henkel.
They're real pioneers withtheir Sonderhof FIPFG
technology.
Elena Bondwell (00:47):
Okay.
Lucas Adheron (00:47):
We're looking at...
New material propertiesdesigned for car parts, how it
applies to sustainablemanufacturing, which is huge
right now, and even somereal-world examples like in
power distribution systems.
Elena Bondwell (00:59):
So what's the mission here?
Lucas Adheron (01:01):
Well, the mission is really to figure out how
this approach, this 50FG, ischanging the game.
how it's redefining precision,boosting efficiency, and
surprisingly, sustainability inmanufacturing.
Elena Bondwell (01:12):
OK, so if you've ever wondered about that
invisible tech that keeps yourgadgets working or your car
sealed up tight.
Lucas Adheron (01:19):
Or how manufacturers are actually
managing to cut costs and theircarbon footprint at the same
time.
Elena Bondwell (01:24):
Then yeah, you're probably in for some real
aha moments today.
We're going to see how a tinycomponent can make a massive
difference.
It's quite fascinating,actually.
So before 50FG really took off,what was the Standard.
The old way of sealing things.
Lucas Adheron (01:40):
Right.
The traditional methods.
Mostly you're looking atpre-cut seals, like pieces
punched out of sheets ofmaterial, maybe EPDM, TPE, that
kind of thing.
Elena Bondwell (01:48):
Okay.
So like pre-formed shapes.
Lucas Adheron (01:49):
Exactly.
And then picture this.
Someone on the assembly lineliterally peeling off a backing
and sticking the seal into placeinside an appliance maybe or a
car door frame.
Elena Bondwell (02:00):
That sounds fiddly.
And slow?
Lucas Adheron (02:03):
It was.
And, you know, while thoseseals did a job, they had
weaknesses built right in.
Think about where two pieces ofa pre-cut gasket meet or where
the ends join up.
Those seams.
Elena Bondwell (02:14):
Potential leak points?
Lucas Adheron (02:15):
Absolutely.
Weak spots for water, for dust,even for noise and vibrations
to get through.
And the manual part, applyingthem by hand, it's not just
slow, it's inconsistent, proneto errors.
Elena Bondwell (02:29):
Especially when you're trying to make...
Thousands of units a day.
Lucas Adheron (02:32):
Right, exactly.
As production scales up andproducts get more complex, that
old method just struggles.
It can lead to a rework,warranty issues, basically a
less reliable product for theend user.
Elena Bondwell (02:43):
Yeah, I can see that.
If you're a manufacturer tryingto grow or just someone buying,
say, a dishwasher, you want itto last.
You don't want leaks caused bya tiny gap in a seal.
Lucas Adheron (02:52):
Those small inconsistencies become big
problems.
Costs go up, quality suffers.
Elena Bondwell (02:57):
Okay, so the old way had issues.
What was the Burke throughthen?
What makes Henkel's IPFG sodifferent, so revolutionary?
Lucas Adheron (03:04):
It's a completely different philosophy, really.
A radical shift.
Instead of taking a pre-madeseal and trying to fit it
perfectly.
Elena Bondwell (03:10):
Which is hard.
Lucas Adheron (03:11):
Which is very hard, yeah.
FIPFG technology forms thegasket directly onto the part
itself.
Elena Bondwell (03:17):
Forms it?
How?
Lucas Adheron (03:18):
Imagine a robotic arm.
moving with incredible speedand accuracy.
It dispenses a liquid foamprecisely along the groove or
surface where the seal needs tobe.
Elena Bondwell (03:28):
Like 3D printing a seal?
Lucas Adheron (03:30):
Kind of, yeah.
It molds itself instantly toevery curve, every contour, and
it creates this seamless,perfectly shaped seal made of
elastomer right there inseconds.
Elena Bondwell (03:41):
Wow.
Okay.
Seamless is the key word there,I guess.
No joins, no gaps.
Lucas Adheron (03:44):
Exactly.
That's the magic.
How does it work?
Well, it's usually atwo-component system.
Polyurethane, maybe silicone.
These two liquids mix right atthe dispensing head.
Elena Bondwell (03:54):
A sophisticated mixing head, I imagine.
Lucas Adheron (03:56):
Oh, yeah.
Typically CNC-controlled,computer numerical control.
So think super precise,computer-guided application.
This mixed foam is dispensed,and then it just cures right
there in place.
It becomes a solid, flexibleseal.
Elena Bondwell (04:07):
And that formed-in-place part is what
eliminates those weak points youmentioned.
Lucas Adheron (04:11):
Precisely.
No seams, no joins means nobuilt-in weak spots.
You get a continuous,uninterrupted barrier.
And the precision is amazing.
We're often talking tolerancesdown to plus or minus 0.1
millimeters.
Elena Bondwell (04:24):
That's tiny.
Way more accurate than stickingsomething on by hand.
Lucas Adheron (04:27):
Oh, absolutely.
You just can't get thatconsistency manually.
Elena Bondwell (04:31):
So for you, the person using the final product,
what does that mean?
It means things are sealedreally, really well, like zero
gap sealing, they call it.
Lucas Adheron (04:40):
Right.
And high sitting resilience,which means it bounces back
after being compressed.
Elena Bondwell (04:44):
And this tech can hit standards like IP68
protection.
Lucas Adheron (04:48):
It can, yeah.
Elena Bondwell (04:49):
Okay, for anyone not up on their IP ratings,
IP68 is basically top-tierprotection against dust and
water, like serious waterresistance, even immersion.
Lucas Adheron (04:58):
It means your electronics, car parts,
appliances, they're properlysealed against the elements,
protected.
It gives you peace of mind.
Elena Bondwell (05:05):
But it's not just how the seal is made, is
it?
The material itself has to beright.
A perfect application won'thelp if the foam isn't up to the
job.
Lucas Adheron (05:12):
Absolutely crucial.
The material is the heart ofthe seal.
And Henkel has options,tailored solutions.
Let's talk polyurethane.
They're Sonderhof Vermipore K31range, for instance.
Okay.
These are two-component PUfoams, and they're engineered
for incredible resilience.
Like, they have thisnear-perfect resetting ability,
often over 95%.
95%
Elena Bondwell (05:33):
reset.
What does that mean inpractice?
Lucas Adheron (05:36):
It means if you compress it like closing a door
or a lid, it springs back almostperfectly to its original shape
time after time.
Think of it as a dishwasherdoor seal.
You open and close itconstantly.
If it doesn't reset well, itdevelops gaps, leaks.
Elena Bondwell (05:49):
Ah.
Ah, okay.
So high reset means it keepssealing properly for longer.
Lucas Adheron (05:52):
Exactly.
It's key for longevity.
Plus, these PU foams are reallystable against hydrolysis.
They don't break down easilywith water exposure and
temperature stable too.
They meet tough automotivestandards like DBL 5452, meaning
they perform reliably in heat,cold, vibration.
Perfect for those demandingIP68 seals.
Elena Bondwell (06:11):
Okay.
So polyurethane sounds greatfor resilience for common but
tough conditions.
What if you need something evenmore extreme?
Lucas Adheron (06:18):
Good question.
Because yeah, it Different jobsneed different tools, different
materials.
Right.
And that's where silicone foamscome in, like Henkel's
Sonderhof Vermisil range.
Elena Bondwell (06:26):
Silicone, right.
Usually good with temperatures.
Lucas Adheron (06:28):
Extremely good.
Vermisil, for example, canhandle a huge temperature range.
We're talking from minus 60degrees Celsius, like Arctic
cold, up to plus 180 C.
And it can even take shortbursts up to 350 degrees
Celsius.
Elena Bondwell (06:42):
Wow.
Okay.
That's serious heat.
Lucas Adheron (06:45):
It is.
And it's typically a closedcell foam.
Imagine tiny bubbles inside,but none are connected.
That makes it exceptionallygood at keeping out water and
gases.
Very weather resistant,chemical resistant too.
Ideal for really toughindustrial uses, outdoor
electrical boxes, chemicalequipment, things like that.
Elena Bondwell (07:02):
So it's not one size fits all.
It's about matching thematerial PU or silicone or
specific grades to the exactneeds of the application.
Lucas Adheron (07:10):
Precisely.
Whether you need that extremetemperature range or the
incredible bounce backresilience for constant use.
It's about getting the perfecttailored seal for the job, like
bespoke tailoring, but forgaskets.
Elena Bondwell (07:21):
Okay, so the seals themselves are incredibly
precise, durable, tailored.
That's great for the product.
But what about themanufacturers?
How does FIPFG change things onthe factory floor?
Does it speed things up, cutcosts?
Lucas Adheron (07:34):
Oh, absolutely.
It's a massive efficiencybooster.
These FIPFG systems, they useadvanced dosing machines.
Henkel makes specialized onesunder the Sonderhoff brand, and
they work incredibly fast andconsistently.
Elena Bondwell (07:45):
Robots doing the work.
Lucas Adheron (07:46):
Often, yeah.
Stationary setups or roboticarms.
It means the application isquick, it's precise every single
time, totally repeatable.
Automation takes out the humanerror, speeds up the whole line.
Elena Bondwell (07:57):
Can you give an example?
Like where has this made a bigdifference?
Lucas Adheron (08:00):
Sure.
A great case study is in theautomotive world, specifically
ceiling car door modules.
Modern car doors are stuffedwith electronics, right?
Window motors, locks, speakers.
Elena Bondwell (08:10):
Yeah, complex bits.
Lucas Adheron (08:11):
Very.
And all that needs protectionfrom rain, dust, vibration.
So the FIPFG solution uses aspecific two-component PU foam,
again from that SonderhoffFermipore K31 family, and it's
applied fully automatically byrobot.
Elena Bondwell (08:24):
Okay.
What's the big win there?
Lucas Adheron (08:25):
Well, a couple of things.
This This particular foam has areally neat combination.
A decent pot life, meaning itstays liquid and workable for a
short while after mixing anddispensing.
Elena Bondwell (08:35):
Giving the robot time to finish the pattern.
Lucas Adheron (08:37):
Exactly.
But then it cures really fast,so the door module can be
handled and moved down theassembly line very quickly.
Shorter cycle times.
No need for big racks of partswaiting to cure.
Elena Bondwell (08:49):
Ah, saving space and time.
Lucas Adheron (08:50):
Definitely.
And another thing, thisspecific foam has a slightly
lower density, about 5% lower.
Sounds small, but it means lessmaterial used per door, which
saves money and makes the doorcomponent a tiny bit lighter.
Elena Bondwell (09:02):
Every gram counts in automotive, right?
For fuel efficiency.
Lucas Adheron (09:06):
Absolutely.
Plus, requires less force toinstall the module, which makes
assembly easier and helps ensurea tight seal, even if there are
slight variations in the parts.
Elena Bondwell (09:14):
That sounds like a win-win-win.
Faster, cheaper, lighter,better seal.
Lucas Adheron (09:18):
Pretty much.
But it's not just cars.
Elena Bondwell (09:20):
Right.
You mentioned powerdistribution.
Lucas Adheron (09:22):
Yeah.
Another great example.
We saw a case where a companymaking electrical enclosures
like cabinets for circuitbreakers and stuff.
They were using those manualpeel-and-stick foam tapes.
It was slow, error-prone,really a bottleneck as their
orders increased.
They needed something faster,better quality, and ideally
something that wouldn't increasetheir costs, maybe even lower
(09:44):
them.
Elena Bondwell (09:44):
Pay classic manufacturing challenge.
Lucas Adheron (09:46):
Yeah, right.
So the solution was putting inan automated FPFG dosing system,
again using FermiPort K31, andthe results were, frankly,
amazing.
Elena Bondwell (09:55):
How amazing.
Lucas Adheron (09:56):
They reported a cost reduction of more than 30%.
30%.
Elena Bondwell (09:58):
That's huge.
Lucas Adheron (10:00):
Huge.
Plus, quality went way up.
Consistency was perfect.
Defects basically disappeared.
And because it's on-demandapplication, they had more
flexibility.
They could produce more faster.
It completely changed theiroperation, turned that
bottleneck into a realadvantage.
Elena Bondwell (10:16):
Okay, a 30% cost cut is seriously impressive.
But isn't the initialinvestment in these automated
robotic systems pretty high?
How do companies, especiallysmaller ones, justify that?
Lucas Adheron (10:26):
That's a fair point.
There is an upfront investment,no doubt, but the return on
investment, the ROI, is oftensurprisingly fast.
Elena Bondwell (10:33):
How so?
Lucas Adheron (10:33):
Well, think about it.
You eliminate the manual laborcost for applying seals.
You drastically cut materialwaste.
No offcuts.
Production speed shoots up.
Quality improves dramatically,meaning fewer rejects, fewer
warranty claims down the road.
Elena Bondwell (10:47):
Okay, so the savings start adding up quickly
across
Lucas Adheron (10:50):
different areas.
Exactly.
It compounds.
So for many manufacturers, it'snot just seen as a cost, but as
a strategic investment.
It makes them more competitive,lets them meet higher quality
demands, and kind offuture-proofs their production.
Elena Bondwell (11:03):
Makes sense.
It's an investment inefficiency and quality.
And you mentionedsustainability earlier, too.
How does 5PFG fit into thatpicture?
Because better products arewhat?
One thing, but making themresponsibly is another.
Lucas Adheron (11:15):
It really ties in strongly.
And it raises that importantquestion about longevity, right?
A high quality product thatlasts longer is inherently more
sustainable, less replacement,less waste.
Right.
And remember that high settingresilience of the Fermipore K31
foams, that ability to recoverup to 95%.
It means housings or enclosuressealed with it can often be
(11:36):
opened and reclosed withoutdamaging the seal for repairs,
for maintenance.
Elena Bondwell (11:40):
Ah, so it supports repairability.
Lucas Adheron (11:42):
Yes.
Think about, say, the dirt trapin your dishwasher.
You need to take it out andclean it regularly.
A good FIPFG seal there meansit stays watertight even after
being opened and closed dozens,hundreds of times.
Or photovoltaic inverters theboxes that manage solar panel
output.
Elena Bondwell (11:59):
Yeah.
Lucas Adheron (12:00):
Being able to easily open them for maintenance
without wrecking the sealextends their service life,
keeps those solar panels workingefficiently for longer.
That's direct sustainability inaction.
Elena Bondwell (12:11):
That's a really good point.
Durability throughrepairability.
What about waste duringmanufacturing itself?
You mentioned less material.
Lucas Adheron (12:18):
Right.
Big difference there.
With FIPFG, you dispenseexactly the amount of foam
needed right where it's needed.
No punching shapes out ofsheets, no leftover scrap
materials, zero punching waste.
You use 100% of the foam.
Elena Bondwell (12:30):
Okay.
Lucas Adheron (12:30):
And we already mentioned the lower density
means less raw materialconsumption overall, better CO2
balance, lighter parts.
It all adds up.
Elena Bondwell (12:37):
And the process itself, any green benefits
there?
Lucas Adheron (12:40):
Definitely.
These two-component foam No
Elena Bondwell (12:43):
big ovens needed.
Lucas Adheron (12:44):
Exactly.
No need for massive,energy-hungry tempering ovens to
cure the seals.
That saves huge amounts ofenergy and upfront investment.
Also, the dynamic misting headsthey use are designed to
minimize waste compared to olderstatic mixing tubes that needed
frequent replacing.
Elena Bondwell (13:01):
How are they cleaned?
Lucas Adheron (13:02):
Ecologically, actually.
Yeah.
Typically with high-pressurewater, not harsh chemical
solvents, which is much betterfor the environment and worker
safety.
Elena Bondwell (13:11):
Water.
Does that use a lot of waterthen?
Lucas Adheron (13:13):
Well, this is pretty cool.
Henkel's even developed rinsingwater recycling systems.
They filter and purify thewater used for cleaning the
mixing head so it can be reused.
Cuts That's
Elena Bondwell (13:24):
clever.
Closing the loop?
Lucas Adheron (13:26):
Yeah.
And digitalization plays arole, too.
Sensors in the mixing headconstantly monitor the process
to ensure quality.
They can also predict whenparts might need maintenance,
avoiding unexpected downtime.
Elena Bondwell (13:38):
Predictive maintenance.
Lucas Adheron (13:39):
Right.
And things like online supportfor troubleshooting can reduce
the need for technicians totravel, cutting CO2 emissions.
The systems can even trackmaterial consumption and
calculate the associated CO2footprint.
Elena Bondwell (13:50):
Wow.
So you get real-time data onthe environmental impact.
Lucas Adheron (13:54):
Yeah.
It's bringing smart, greenmanufacturing principles right
into the sealing process.
Elena Bondwell (13:58):
It really shows how advanced tech and
sustainability can go hand inhand.
It's not always a trade-off.
Lucas Adheron (14:04):
Not at all.
In this case, the advanced techenables better sustainability.
Elena Bondwell (14:08):
So wrapping this up, then, from keeping our car
doors tightly sealed againstwind and rain to making sure a
solar inverter can be easilyrepaired to last longer, this
deep dive really shows howformed in place foam gaskets
are, this sort of silent, hiddenpowerhouse, driving efficiency,
saving costs, and boostingsustainability in so many
(14:30):
different industries.
It's impressive stuff.
Lucas Adheron (14:31):
It really is.
And if you connect into thebigger picture, it's just a
fantastic example of howmaterial science the actual foam
chemistry and automation, therobotic application are coming
together.
Elena Bondwell (14:42):
It's like converging.
Lucas Adheron (14:43):
Converging to not just make products perform
better and last longer, but alsoto genuinely reduce our
environmental impact across thewhole life cycle, from making it
to using it to repairing it.
Elena Bondwell (14:53):
It really challenges that old idea that
high tech automatically means ahigher ecological price tag.
Lucas Adheron (15:00):
Exactly.
It proves innovation canactually be the key to a more
sustainable approach.
Elena Bondwell (15:04):
Okay, so here's a final thought to leave you
with.
As you go about your Maybenotice those seals.
Or maybe just think about allthe other unseen bits of
technology, the hidden gasketsand components quietly doing
their jobs everywhere.
How many other invisibleinnovations like FitPFG are out
there, quietly revolutionizingindustries, making things more
(15:25):
efficient, more sustainable,right under our noses?
Lucas Adheron (15:28):
Makes you wonder what the next hidden game
changer will be.
Elena Bondwell (15:30):
It really does.
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