Higher processing productivity – in comparison to sheet metal, wood, concrete, castings and other plastic processes. Also offers superior dimensional accuracy and repeatability when compared to fabricated or machined parts.

More strength with lower part weight – thicker wall sections, up to .400 thick, give parts significantly higher strength than injection molded or other processed parts.
Size flexibility – parts from 8 ounces to 45 pounds can be molded.

Lower tooling costs and longer tool life – structural foam molds are typically made out of aluminum and are under far less stress and pressures, greatly reducing wear and tear.

Improved appearances – structural foam lets you easily design-in many attractive features - such as ribs, bosses, hinges and curved surfaces - than most other processes.

Gas CounterPressure - Counterpressure is a process that's capable of improving the aesthetics of structural foam parts. In this process parts will gain an injection quality surface. The swirl and splay that is associated with foam molding is eliminated. For more information click here.

Structural foam molding is a low-pressure injection molding process that utilizes a chemical blowing agent or nitrogen gas. Structural foam molding is an extension of the standard injection molding process, but operates under the theory of delivering a ‘short-shot’ into the mold. Parts molded in structural foam are typically larger, have a much higher strength-to-weight ratio, and are virtually free of stress and sink marks. Due to the process, solid skins are formed against the walls of the mold, while the interior of the part remains foamed, which allows a typical reduction in part weight by 5-20%.

Due to the nature of structural foam molding, it leaves a swirl pattern in the surface of the part, which can require a painting operation to deliver a professional look. Structural foam parts are excellent candidates for various paint and shielding media.