Customizing Gas Assist Molding for Complex Industrial Applications
Industrial plastic components aren’t getting any simpler. From heavy-duty housings to detailed enclosures, manufacturers are expected to deliver parts that hold up under stress, meet tight cosmetic standards, and support streamlined production timelines. For many of these applications, gas assist molding provides a reliable solution – but it’s the customization behind the process that makes the biggest difference.
At DeKALB Molded Plastics, gas assist molding is tailored to fit the unique challenges of each project, supporting complex part designs without compromising strength, aesthetics, or efficiency. Read on to see how our customized approach helps manufacturers tackle their toughest industrial designs with confidence.
Supporting Complex Industrial Designs with Confidence
Gas assist molding is already familiar to many OEMs and engineers. The ability to mold hollow sections and reduce material usage makes it a smart fit for large parts with varying wall thicknesses. But complexity comes in many forms – geometry, structural needs, surface finish, and integration with other components – and not every provider is equipped to handle that.
DeKALB focuses on dialing in the process to match the specific needs of industrial projects. That means refining gas channel layouts, balancing structural support with visual requirements, and managing cycle times with precision. For applications where function and appearance matter equally, this level of control becomes critical.
Equipment and Expertise That Adapt to the Part
Customization begins with the right foundation. We use both Milacron Structural Web Gas Assist and Bauer Gas Assist technologies, supported by multi-nozzle systems and press capacities ranging from 300 to 750 tons. This flexibility allows for molding larger parts with more detailed features and for combining gas assist with structural foam techniques where needed.
The approach isn’t one-size-fits-all. Gas flow paths, resin selection, mold design, and processing conditions are all considered based on the end-use environment and performance expectations. Whether the goal is to eliminate sink marks, reduce weight, or boost rigidity, DeKALB works closely with customers to meet the mark.
Balancing Strength, Appearance, and Efficiency
Successful gas assist molding depends on more than filling a cavity of molten plastic with nitrogen. Achieving stiffness, maintaining part integrity, and creating a clean visual finish all require deliberate engineering. DeKALB’s process forms hollow gas channels through thicker wall sections, displacing polymer into those areas and leaving behind a smooth surface with minimal warping.
Lower cavity pressure reduces wear on the tooling and makes it possible to run parts on machines with less tonnage, adding efficiency without compromising quality. Cooling time also drops, thanks to the hollowed sections, which speeds up cycle time and increases throughput.
Resin selection plays a key role, especially for parts exposed to heat, impact, or chemical environments. DeKALB regularly works with engineered resins and glass-filled materials, matching material properties to the mechanical demands of each part.
Built for Demanding Market Segments
Gas assist molding supports a wide range of industrial and commercial markets, each with its own set of challenges for performance, safety, and appearance. At DeKALB Molded Plastics, we work closely with customers to develop tailored solutions across several key industries:
Medical Equipment and Structures
From MRI helmets to dialysis components and hospital bed frames, gas assist molding helps create lightweight, ergonomic housings that meet strict regulatory and structural demands. DeKALB’s expertise supports medical OEMs by delivering parts that hold up under sterilization, resist cracking, and meet dimensional tolerances.
Material Handling and Bulk Transport
For food, textile, and chemical applications, we use gas assist molding to create rigid yet lightweight containers, pallets, and enclosures. These parts benefit from reduced wall thicknesses, integrated handles or stacking features, and weight savings that improve transport efficiency.
Safety Enclosures and Infrastructure Devices
From energy-absorbing barriers to equipment cases and structural inserts, our molded safety products support high-impact, high-visibility environments. Gas assist enables thick-walled designs to stay strong while minimizing material use and tooling costs.
HVAC and Air Movement Solutions
Airflow shrouds and ventilation housings benefit from gas assist molding’s ability to reduce part weight while maintaining stiffness and flow efficiency. Complex geometries and smooth internal surfaces can be produced with precision, supporting performance in ducting and air control systems.
Protective Flooring and Structural Panels
DeKALB produces rugged, chemical-resistant panels for use in facilities that demand high durability, such as cleanrooms, warehouses, and agricultural buildings. Gas assist molding allows for large panel sizes with reduced warping, ideal for snap-fit or modular installation.
Architectural Equipment and Enclosures
Architectural panels, display housings, and custom molded equipment covers all benefit from the surface quality and structural reliability of gas assist. For applications where finish and form matter as much as function, this process offers a flexible solution.
Beyond Molding: A Complete Manufacturing Partner
Support doesn’t stop once the part comes out of the press. DeKALB offers a full suite of value-added services that streamline production and simplify supply chains. These include:
- In-house mold design and tooling support
- Post-mold painting and decoration
- Kitting, labeling, and subassembly
- Inventory management and packaging solutions
For customers managing multiple part numbers or high-mix, low-volume projects, having a partner that handles more than just molding can be a significant advantage. DeKALB’s team steps in early to align project goals, prevent downstream issues, and deliver dependable results.
Ready to Tackle Your Toughest Designs
Industrial applications demand more from molded parts – and from the companies that make them. DeKALB combines decades of experience, hands-on engineering, and a flexible mindset to make gas assist molding work for each unique challenge.
Looking to improve strength, appearance, or production speed on a complex molded part? Let’s explore how a customized gas assist solution can bring your next project to life – contact us today.