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Advancements in the field of polyolefin resins have enabled new classes of thermoplastic bead foam products to be created which provide enhanced physical properties. These new products are capable of improved performance due to the advancements that have been made in the area of polyolefin resin catalyst systems, specifically those employing the new Metallocene catalyst method for production. With this new technology, Expanded Polyolefin bead foams such as Expanded Polypropylene (EPP) are making their way into new automotive applications, that just a few years ago were not possible. These advances have made it possible to comply with the stringent design, testing, and qualification requirements that headliner systems must meet.

Recent advancements in the field of polyolefin resins in the area of PP+PE copolymers, impact co-polymers, and homo-polymers have allowed for the creation of a new class of thermoplastic foam products. These new products are capable of improved performance due to the advancements that have been made in the area of polyolefin resin catalyst systems. These new Metallocene catalysts are being employed to create resins with improved mechanical properties that otherwise were not available using the traditional Ziegler-Natta (Z-N) catalyst systems currently being used to produce a majority of the thermoplastic materials available today. This paper will describe these recent advancements and how they allow for improved properties to be realized in the area of expanded bead foams used in the construction of molded automotive interior components used in the occupant safety system designs.