Structural Foam Molding

Structual foam molding is an injection molding process that creates structrually sound and light weight parts that are less likely to warp. A foaming agent is mixed with part resin while still in pellet form. As the resin and foaming agent is heated by the barrel and injected into the mold, the foaming agent turns into gas. Less material is required because the gas bubbles expand until the cavity is filled. As the material pushes against the wall of the mold it creates a thick skin while leaving the inside of the part with a cellular like structure.

Due to the unpredictable nature of the gas, structural foam parts have an uneven surface color; you can visibly see tints and shades of the chosen color in a swirl-like pattern. For parts that require high cosmetics, we offer in-house painting services.

With our expertise in injection molding and sheet metal fabrication, we can help you convert sheet metal parts to structural foam or form the sheet metal base that supports the structural foam skins in-house.

Structural Foam Illustration

Benefits to Structural Foam Molding

Lighter Weight Parts

Reduced Cost Due to Lower Material Use

Increased Part Stiffness and Strength

Achieve Thick Parts Without Sink Marks

Minimal to Zero Warpage

Mammogram Machine

When to Choose Structural Foam Molding

Structural foam molding is a great option for large, thick parts. It is widely used for medical and industrial products including; medical carts and machines, self-serve kiosks, ice makers, and industrial flooring, bezels, and equipment. 

Structural Foam Illustration

Benefits to Structural Foam Molding

Lighter Weight Parts

Reduced Cost Due to Lower Material Use

Increased Part Stiffness and Strength

Achieve Thick Parts Without Sink Marks

Minimal to Zero Warpage

Mammogram Machine

When to Choose Structural Foam Molding

Structural foam molding is a great option for large, thick parts. It is widely used for medical and industrial products including; medical carts and machines, self-serve kiosks, ice makers, and industrial flooring, bezels, and equipment. 

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