Cellbond: Pressload Energy Absorber

PressLoad is a low cost component. It is particularly suitable for high volume mass production as it can be manufactured from a range of metals sheets (cold forming) or thermoplastic materials (thermoforming/injection moulding). The fundamental structure of the PressLoad principle, whether in its raw shape or sandwiched has also the advantage of having an open structure along its length, making it possible for wiring to pass along the panel / energy absorber.


  • Excellent energy absorption to weight ratio
  • Cost efficient
  • Recyclable
  • Repeatable and consistent HIC values
  • Flexible design
  • Temperature stability
  • Good performance under angular impacts
  • Ageing stability
  • Minimum packaging space
  • Exceptional flexural properties when sandwiched

A recently completed test programme shows that PressLoad performs on an equally high level as Honeycomb

and out performs other energy absorbers such as: PUR Foam, EPS, Plastic ribs, etc.

Besides superior performance, PressLoad allows for a low cost, fully automated production method for high quantities; plastic injection moulding.

The PressLoad concept

The PressLoad concept offers lightweight, low cost energy absorption for the car, rail and architectural industry. Its innovative structure delivers excellent energy absorption characteristics.

PressLoad uses a specially designed geometry, similar to an egg box. Its arrangement of conical shells provides strength and the ability to deform in a predictable way. The flat tops of the cones and the ability to mould flaps (as can be seen in the picture below) provides different options from easy fixing to headliners or other interior parts. PressLoad offers further the ability to be designed in an exact shape following the body in white or other interior trim as well as the exact required crush strength. Its design versatility enables PressLoad to be suitable for various applications.

Material Range

The Pressload energy absorber’s geometry provides its

excellent performance using various materials and different processes (injection moulding and thermo/cold forming):

  • Thermoplastics (PP, PC, ABS/PC, etc.)
  • Metals (aluminium alloys, magnesium, steel, etc.)
  • Thermoplastics
  • Other materials upon request


Occupant protection:

  • Roof lining
  • A, B and C pillars
  • Dashboards
  • Footwell
  • Side impact
  • Grab handles
  • Anti-submarining

Pedestrian protection:

  • Bonnets
  • Bumpers

“Tailored” applications available to specific customer requirements.

Our Services At A Glance

Cellbond offers complete packages of engineering and manufacturing services including injection moulding and tool making. Further services include:

  • Consultancy
  • Design
  • Prototyping
  • Simulation (FE-modelling)
  • Dynamic, static and climatic testing
  • Full-scale production