Foamed Celluloid Process Using Expandable Beads

Technology Overview: A scalable molding process for foamed celluloid that uses physical‑blowing‑agent (PBA) presoaking of small, uniform celluloid pieces followed by thermal foaming in a mold to achieve target densities and geometries. For very low‑density parts, the process introduces a pre‑expansion step prior to final molding, enabling lightweight, moldable components suitable for energetic applications where combustible, low‑residue structures are desired. ,

Industry Pain Point: Conventional felt‑fiber or non‑porous celluloid parts can be labor‑intensive to produce, sensitive to moisture, and may leave residue after combustion—issues that impact performance and safety in propulsion systems and other energetic uses.

NJIT Solution: Introduce a three‑ or four‑step expandable‑bead foaming route that yields economical, mold‑ready foamed celluloid parts across a broad density range (≈0.2–1.25 g/cc) with improved processing flexibility and clean burn characteristics. ,

Key Features & Advantages

• Presoak + mold‑foam process for repeatable density/shape control.
• Optional pre‑expansion step to achieve ultra‑low densities while retaining moldability.
• Supports low‑residue, combustible components for energetic systems.

Development Stage: TRL 4–5 – Laboratory/benchtop validation with issued patent embodiments.

Target Markets

• Defense & aerospace (combustible cases, energetic components)
• Specialty molded parts requiring clean combustion
• R\&D suppliers for propellants and pyrotechnics