Structural Foam Molding

Structural foam molding is a low pressure injection molding process where the plastic melt is foamed with nitrogen gas or a chemical blowing agent. As the plastic fills the mold, the wall of the part solidifies against the cold mold wall. A thin layer of plastic solidifies along the mold wall. This thin layer forms a skin structure over the foamed inner core. The thin outer (solid) wall is supported by the interior cellular foam structure. This process can be used on many different sized parts, small to large, to produce a stronger, and potentially longer lasting part. Many large parts require thicker walls than standard injection molding can produce.

Structural foam molding allows for the injection molding of such parts through the addition of a foaming agent. Any injection moldable plastic can be used in the structural foam molding process. Structural foam molding allows for the injection molding of such parts through the addition of a foaming agent.

A combination of the lower viscosity of this mixture and the thicker cross section of the molded part, results in less injection and clamping pressures required and less stresses created while injecting the plastic into the mold. The lower pressures and forces involved allow more economical molding equipment and tooling to be utilized. This leads to enormous parts being mass produced or multiple parts being simultaneously molded on the same machine cycle.