Structural Foam

images 1Structural foam is a low-pressure form of injection molding, which utilizes most thermoplastics, (including post-consumer regrind), to mold rigid product, which can have thicker walls and higher stiffness-to-weight ratios than standard injection molded product.

In the structural foam process, a physical or chemical blowing agent is mixed in with the resin. The resin is shot into the cavity, but not completely filled or packed out. The blowing agent expands to push the resin to the extremities of the cavities. As the part cools, the internal pressure of the foaming action takes up the internal shrinkage, and reduces sinks over ribs or heavy cross-sections.

Advantages of the Structural-Foam process:

There are many advantages of the structural foam process which combine to provide an economical advantage over other processes, and allow production of parts which can’t be matched by any other process. Following is a list of many of the advantages of the Structural-foam process:

  • Low cost tooling with the same molded-in detail and features possible in standard injection molding
  • Multiple parts and multiple tooling can be run on a single machine.
  • Two different materials and or two different colors can be run at the same time.
  • Product can easily be gated at multiple points on the part, which can be strategically positioned to optimize filling, and processing.
  • The process utilizes low-pressure to mold the parts which results in low stress and warpage in the parts.
  • The low pressure part of the process allows molding of large parts with low machine tonnage.
  • The process allows a wide range of design flexibility.
  • Superior part and process repeatability are possible with the process.
  • High strength-to-weight ratio.
  • Reduced part weight while maintaining high stiffness-to-weight ratio.
  • Can mold medium wall thickness through very thick wall sections with minimal sink marks.
  • Reduced weight of 10 to 20% over solid plastic part.
  • Total shot weight of up to 200 pounds.

Click Structural Foam for a one page PDF handout to better understand our capabilities. 

* PPX SF1                Easy Flow FR PPE/PS Blend
* PPX SF2                Standard Flow FR PPE/PS Blend
* PC SF FR               5% Glass Filled FR Polycarbonate
* PC SF FR1             10% Glass Filled FR Polycarbonate
* PC SF FR G20        20% Glass Filled FR Polycarbonate
* PC SF FR G30        30% Glass Filled FR Polycarbonate
* TP SF G10             10% Glass Filled PBT
* TP SF G30             30% Glass Filled PBT
* TP SF FR G10        10% Glass Filled FR PBT
* TP SF FR G30        30% Glass Filled FR PBT

Additives, Modifiers, and Reinforcing Agents: 

Additives- UV stability, easy release (mold releases), colorants, and other stability additives

Modifiers- Flame retardants, impact modifiers, flow enhancers

Reinforcing Agents- Glass fibers, mineral filler

*Please find the listed data sheets above, utilizing the data chart selection tool below*