applications, material and manufacturing of foam roller

1. Universiti Kebangsaan Malaysia (UKM)
The National University of Malaysia
Faculty of Engineering & Built Environment
Department of Mechanical and Manufacturing Engineering
Our Lecturers:
Prof. Dr. Andanastuti Muchtar
Dr. Nabilah Afiqah binti Mohd Radzuan
Dr. Nashrah Hani binti Jamadon

2. FOAM ROLLER
BY THE BORDERS
KKKM2833 Manufacturing Processes
Semester 2 Session 19/20

3. MOHD HAZRIL AMIR BIN
MD ESA
AIZAD AL WAFI BIN
ZULKIFLI AMIN
DANIAL IMRAN BIN
AHMAD SHARIFFUDIN
QUIK HUI YI

4. APPLICATIO
N OF THE
PRODUCT
DANIAL IMRAN BIN AHMAD

5. Self-Myofascial Release
- To loosen up the tightness at common areas.
- Position yourself on top of the roll (at the
common area) and use the weight of your body
to roll back and forth slowly.
Self-Accupressure
- To relax the muscles.
- Place your foam roller under your shoulder
and place both of your arms over the chest.
Lift your hips and hold up for 60 seconds.
Sources: https://www.shape.com/fitness/workouts/10-ways-use-foam-roller?slide=8d2c75cd-1ac6-4b9e-8343-0729bc892658#8d2c75cd-1ac6-4b9e-8343-0729bc892658
https://www.healthline.com/health/foam-roller-benefits#muscle-pain

6. Next level pushup
- To engage and focus more on core muscles
even more challenging.
- Place both of foots on top of the foam roller
during a pushup.
- This technique will force your body to work
harder to stabilize.
Use as a Yoga Prop
- Slip the foam roller under your knees to
aid relieve some pressure.
- Yoga postures and poses will help
individual to balance and relieve the
muscles even better.
Sources: https://www.shape.com/fitness/workouts/10-ways-use-foam-roller?slide=8d2c75cd-1ac6-4b9e-8343-0729bc892658#8d2c75cd-1ac6-4b9e-8343-0729bc892658
https://www.healthline.com/health/foam-roller-benefits#muscle-pain

7. Strengthen Your Core
- To force your core to work harder and train to
balance the body on unstable surface.
- Lie on the roller (should be on your length of
spine) with your knees bent and slowly lift up
the left foot of the floor. Make sure you clasp
your hands behind your head and elbows out.
Extend your stretch
- The softness of the roller is a nice prop to
use for stretching.
- As shown in the picture, one can increase
the range of motion in a hamstring stretch
by propping one foot up on the roller.
Sources: https://www.shape.com/fitness/workouts/10-ways-use-foam-roller?slide=8d2c75cd-1ac6-4b9e-8343-0729bc892658#8d2c75cd-1ac6-4b9e-8343-0729bc892658
https://www.healthline.com/health/foam-roller-benefits#muscle-pain

8. Add some Proprioception Power to your
strength routine
- Proprioception is a signaling system of your
body and brain training to help improvise your
balance.
- This exercise will work to engage the system
and help to improve your reaction time.
- Place the roller under your back foot during a
lunge and row combo as shown in the picture.
Safely crack your back
- Lie your back carefully on the foam roller with
your knees bent and feet flat on the ground.
- Slowly roll your body over the roll and use
your legs to guide you.
Sources: https://www.shape.com/fitness/workouts/10-ways-use-foam-roller?slide=8d2c75cd-1ac6-4b9e-8343-0729bc892658#8d2c75cd-1ac6-4b9e-8343-0729bc892658
https://www.healthline.com/health/foam-roller-benefits#muscle-pain

9. MATERIAL

10. Closed-cell bead foam
based on polyolefins
Chemically inert
• The material is non-toxic and not chemically reactive
• Unharmed to direct skin contact
Vibration absorption
• Densities range from 15 to 200 grams per liter
• Can withstand force during exercise
Waterproof
• Resistance to water even in conditions of high humidity
• Makes it an ideal material due to hygiene
Thermal Insulation
• Stable from -40 to +60 °С
• Fire-retardant agents can be added to prevent microbial
growth
Expended
Polypropylene
(EPP)

11. CHEMICAL
COMPOSITION

12. polymerisation
Propene
Formula = (C3H6)n
IUPAC ID = poly(propene)
Density = 0.855 g/cm3,amorphous
0.946 g/cm3, crystalline
Classification = Polymer, Thermoplastic
Formula = C3H6
IUPAC ID = Propene
Molar Mass = 42.08 g/mol
Density =1.74 kg/m³
Propene Polypropylene

15. WHY EPP FOR FOAM ROLLER？

17. Product density (kg/m3) 20 40 60 80 100
Tensile strength (kPa) 250 600 880 1000 1300
25% Deformation (kPa) 80 220 430 500 780
50% Deformation (kPa) 150 390 560 930 1340
75% Deformation (kPa) 330 700 1050 2150 3370
(DATA ABOVE IS REFERED FROM SYNPRODO: WHAT IS EPP?)

19. MANUFACTURING OF
FOAM ROLLER

20. STEP IN PRODUCTION
Material
Selection, (EEP)
STEP 1
Plastic extrusion
STEP 2
Pre- Expansion
STEP 3
Steam-chest
moulding
STEP 4

21. STEP 1 & STEP 2
1. Material Selection
Expanded Polypropylene
(EPP) is thermoplastic
polymers that the most
versatile closed-cell bead
foam that provides various
range of properties for foam
roller
2. Plastic extrusion
Starts with put the plastic material in (pellets,
granules, flakes or powders) from hopper to the
barrel of extruder. Then, the beads will slowly
melted by mechanical energy by turning screw.
End of that, molten polymer will flow into die,
which shapes the polymer that will harden
during cooling.

22. STEP 3 & STEP 4
3. EXPANSION
The blowing agent inside raw beads
are exposed to a heat source,
normally steam that will lead the
beads to increase size up to 50
times.
4. EPP MOLDING
These EPP foam beads can be
placed in mold, allowing them to
form the desired shape. Steam-
chest molding. First, closing of the
mould. Secondly, filling of the mold
followed by steaming. Next, cooling
process take place and lastly
ejection of molded part.

23. https://www.decathlon.my/

24. • Decathlon Malaysia
https://www.decathlon.my/
• Expanded polypropylene: the benefits of a high-tech material(25.06.2019)
https://ventsworld.com/publications/expanded-polypropylene-the-benefits-of-a-high-tech-material.html
• FoamTech. The Foam Innovator
https://www.foamtechchina.com/epp-expanded-polypropylene-
foam/#:~:text=WATERPROOF%20AND%20BUOYANCY,and%20ensures%20optimal%20water%20obstruction
• Jessica Smith (31 October 2019), 10 Creative Ways to Use a Foam Roller (Besides Rolling Out Sore Muscles)
https://www.shape.com/fitness/workouts/10-ways-use-foam-roller?slide=8d2c75cd-1ac6-4b9e-8343-
0729bc892658#8d2c75cd-1ac6-4b9e-8343-0729bc892658
• Lee EK. Novel manufacturing processes for polymer bead foams. Universityof Toronto; 2010
• Synprodo(2018). What is EPP?
https://www.synprodo.com/what-is-epp/
• What are the benefit of foam roller?
https://www.healthline.com/health/foam-roller-benefits
REFERENCES

25. FROM THE BORDERS