Structural Foam Molding

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%. Structural foam parts are excellent candidates for various paint and shielding media.

Key Advantages & Benefits of
Molding Parts in Structural Foam:

  • Higher processing productivity in comparison to sheet metal, wood, concrete, castings and other plastic processes. 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.
  • Structural foam lets you easily design attractive features, such as bosses, hinges and curved surfaces.
  • Flexibility with ability to produce parts from 8 ounces to 45 pounds.
  • 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.
  • Highest strength to weight ratio compared with traditional manufacturing methods
  • Can replace sheet metal, metal castings, wood, fiberglass in a variety of applications