• At the Centre of
    Intelligent Design

    True innovation is creating products the customer didn’t even know they needed.

Through strategic partnering, we are able to work with our key suppliers to jointly develop unique materials for specific applications. Key areas for our product development are based around “light-weighting” (the need to reduce weight) and the demand for higher temperature performance, especially around the engine compartment in the Automotive market.

Avon Group has developed a family of cost effective polyurethane foam Acoustic materials to function in Automotive applications. Our rigid PU foam not only offers excellent sound attenuation and absorption performance compared to other materials, but are also lightweight and recyclable.

Typically glass fibre products are in the range of 600-1200g/m2. Our Lightfoams are in the range of 120-340g/m2, meaning over an average 2m2 Acoustical requirement, we can reduce a vehicles weight by up to 2kg.

  • Lightweight
  • Conformable
  • Recyclable
  • Hydrophobic
  • Oleophobic
Material Innovation

The reduction of fuel consumption and CO2 emissions is one of the most important challenges facing the Automotive industry.

One way to reduce consumption is by reducing a car’s weight. About one-third of a passenger cars’ total fuel consumption directly depends on its weight.


Expanding our increasingly popular ‘Airflow’ range, Avon Group have through research and development with its partners, come up with new lightweight Foam ducting applications. Our modified PP Foam is recommended for interior and exterior applications that require enhanced mechanical and thermal performance. Temperatures of up to 190°c can be met.

These carry on with the main attributes of better Acoustic performance, are lighter and more thermally advanced than standard rigid plastic ducts.

  • Reduces fuel consumption
  • Acoustically highly efficient
  • High temperature range
  • Evolution
  • Greener


Innovators in Lightweighting
Innovators in Acoustic Technology

Vibration tuning, barrier technology and sound attenuation are just a few of the techniques used to isolate the passenger cabin from road and vehicle noise.

Sound attenuation is usually achieved through the use of Foam or fibre materials for Automotive insulation, designed specifically to convert sound energy into another form. Dense barrier materials, or simple scrims, can be used in conjunction with absorbers to maximize Automotive insulation performance by creating composite solutions.

In combination with cover fleeces, non-wovens or foils, our rigid PU Foams are extremely light and self-supporting. These are therefore ideal for a wide range of sound absorbing and insulating products in Automotive applications.

We have at our disposal a number of different processing methods including Heat sealing (Edge sealing), Thermoforming, Vacuum forming, Moulding, 3D profiling and simple Die-cutting.

  • Lightweight
  • Recyclable
  • New Materials
  • Expertise
  • Highly Efficient

At Avon Group we pride ourselves on our ability to continually exceed our customers’ expectations, in the fields of Acoustic and Thermal Insulation management.

From basic polyester, polypropylene and blended waddings to high performance laminates and engineered composites, which use technical Acoustic scrims and high temperature foils, we are able to create products to suit most applications across a wide range of market segments.

Our ability to combine materials in a variety of ways, give us the capability to “fine tune” products to solve specific Acoustic or Thermal issues.

Avon Group has developed a family of cost effective polyurethane Foam Acoustic materials to function in Automotive applications. Avon Group PU not only offer excellent sound attenuation and absorption performance compared to other materials, but also are lightweight and recyclable.

  • Lightweight
  • Conformable
  • Recyclable
  • Hydrophobic
  • Oleophobic

We aim to become the centre of Innovation within our areas of expertise.

3D Printing

Re-Inventing the way we work

Why wait? Avon Group’s prototyping facilities virtually eliminate your product lead-times, enabling for fast turnaround of production intent parts and quick verification of your product design.

We can support a variety of rapid prototyping solutions. 3D printing technologies include SLA, SLS, Polyjet, and FDM. A variety of materials ensure we can produce soft and rigid parts.

Smart prototyping options and manufacturing solutions minimise the costs and time of design through to production. We can now measure prototype and development part production in hours, rather than days or weeks

Polyjet 3D Printing
How does it work?

A carriage with four or more inkjet heads and ultraviolet (UV) lamps traverses the work space, depositing tiny droplets of photopolymers – materials that solidify when exposed to UV light. After printing a thin layer of material, the process repeats until a complete 3D object is formed.

Further Advanced Prototype
/Production Capabilities

Vacuum cast tooling can be produced from an SLA model, enabling a silicon tool to be made. This can then be used to make small batch runs of the prototype or production parts. Parts are made from polyurethane and, such are the large range of these materials, almost any material can be imitated.

Using this method, it is possible to over-mould and include inserts within the component.

3D Printing – a step by step guide

  • step one

    Receive customer CAD or design component in 3D CAD

  • step two

    Convert CAD for 3D printing and set up layout in the printer

  • step three

    Print parts

  • step four

    Clean the parts and they are ready to use