Automotive Manufacturer of Stratas™ headliner substrates

Stratas headliner with alcantara

Acoustical lightweight solutions

Stratas™ headliner substrate materials can be found in over 40 vehicle programs, including North America’s best selling sports cars, sedans, crossovers and SUVs. Our latest innovation, the Stratas 3D™ dry substrate board, provide an unparalleled combination of lightweight, high acoustics and strength.

Stratas headliner products

Why Stratas?

Foam blocks

Foam sheets

Substrate boards

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headliner-foam-buns
headliner-substrate-foam-sheets
headliner-substrate-boards

See our benchmark studies and learn how Stratas outperforms competing headliner materials.

Foam blocks up to 100 feet in length for both wet and dry processes.

Sliced polyurethane foam sheets for both wet and dry processes from 3mm to 30mm thick.

Six thermoformable substrate board grades are available in a wide range of thicknesses and weights to meet any strength and acoustics requirements.

Why Stratas?

polyurethane-foam-cell-structure

See our benchmark studies and learn how Stratas outperforms competing headliner materials.

Foam blocks

headliner-foam-buns

Foam blocks up to 100 feet in length for both wet and dry processes.

Foam sheets

headliner-substrate-foam-sheets

Sliced polyurethane foam sheets for both wet and dry processes from 3mm to 30mm thick.

Substrate boards

headliner-substrate-boards

Six thermoformable substrate board grades are available in a wide range of thicknesses and weights to meet any strength and acoustics requirements.

Five reasons to use Stratas 3D™ headliner substrates

Lightweight, acoustical and thin

Every layer of the Stratas 3D™ composite structure is entirely new, including the polyurethane foam core’s formulation, fiberglass reinforcement design and polymeric adhesive type. What does this all mean?

500GSM, 4mm thick and high sound absorption. No other material can match this combination of weight, thickness and acoustics.

Lightweight headliner substrate

Superior high temperature performance

In the latest environmental stability study comparing Stratas 3D™ to current production polypropylene and wet process polyurethane foam substrates, we empirically proved Stratas 3D™ outperforms competing technologies.

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High elongation and deep draw

One of the development goals for Statas 3D™ was to provide greater design freedom and allow for deeper draw. Compared to the previous generation, elongation has increased by 50%. This allows for more complex shapes and sharper angles to be formed without risking substrate tears (blowouts).

Formed headliner A-side finish

Improved surface appearance

The substrate board’s surface plays a strong factor in how smooth the finished headliner’s surface and edges will be. As coverstock materials have become thinner, wrinkles, veins and other visual imperfections stemming from the substrate board becomes more apparent.

Stratas 3D™’s new reinforcement layer design encapsulates fiberglass more tightly than before, resulting in smoother finishes and lowered scrap rates.

Stratas dry PU substrate appearance

Enhanced thermoformability and molding strength

Stratas 3D™’s processing window has been significantly widened over the previous generation, helping to lower scrap rates and increase cycle times.

Stratas dry PU molding strength

Flat foam block slabs

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Continuous foam pour

Foam is pulled away from the mixing head as it rises to maintain even chemical distribution and excellent consistency from top to bottom and side to side.

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Flat blocks

While flat blocks up to 100 feet are available, it is typically cut down to between 4 to 6 feet to match the formed headliner’s length.

foam-block-grades

Wide foam grade selection

Various foam grades for both thermoform and thermoset processes are available from the same continuous pour line.

Substrate foam sheets

Precise block preparation

Custom built sensors are in place to measure any unwanted vibrations in the band saw during the block preparation process. Each block is cut to exact specifications.

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Precise block loading

The loading process for foam block slitting is laser guided and blocks are securely held in place via a vacuum table. Blocks will not be fed into the the horizontal band saw until the alignment is perfect.

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Precise slicing

Custom built load censors are installed to measure unwanted vibrations or “blade chatter” in the horizontal band saw during slitting process. Each sheet is measured for thickness and the machine will automatically shut down if foam sheets fall outside of acceptable thickness tolerances.

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Thermoformable substrate boards

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Wet versus dry PU

On many occasions, we have been told thermoset (wet adhesive) headliner substrates are superior to thermoform (dry adhesive) substrates. Our two year study says otherwise.

wet vs dry PU vs pp report

Myth #1: Wet has better thermal stability

In a weight and thickness neutral study, we compared current production wet Bill Of Materials (BOMs) against our dry Stratas 3D™ substrate boards. At lower weights, Stratas 3D™ significantly outperforms the wet headliner substrates.

wet-vs-dry-lower-cost-myth

Myth #2: Wet headliners are always cheaper

Conducted in partnership with one of our customers, the “wet vs dry” study revealed Stratas 3D™ had lower scrap rates and better repeat ability than comparable wet substrates. Further, some wet headliners required a two-step process, whereas Stratas 3D™ headliners only required one.

weighted-cantilever-sag-test

Myth #3: Wet is just better

To definitively prove Stratas 3D™ dry board is unique and superior to other thermoform materials, we conducted a very tough weighted cantilever sag test against other production substrates. This test exceeded standard OEM requirements and showed Stratas 3D™ significantly outperforming weight and thickness equivalent reinforced polypropylene samples.

call-us-Stratas-composite-materials

+1-416-433-9586 

Speak with a Product Manager

to learn more about how Stratas

can lightweight your vehicle.

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