Particle foams offer a unique combination of low density and high energy absorption capability. The heterogeneous cell structure and the complex deformation behavior especially in compression mode complicate their use and part dimensioning. As the design of lightweight structures requires efficient and reliable knowledge about the material properties, the determination of effective homogeneous material properties is needed. The presentation will give an insight into the research activities of the FOREL-project SamPa. Based on a fundamental experimental analysis of the elasto-plastic deformation behavior of an expanded polypropylene (EPP) bead foam, a numerical model is established which is able to predict the material deformation behavior over a wide range of temperatures. As overmolding of the bead foam is a promising opportunity for future foam applications, generic manufacturing trials are performed. The experimental and numerical results are used for the deviation of design and manufacturing guidelines for particle foam composite injection molding.