The Benefits of Recycled Resin in Structural Foam Molding
Building Sustainability into Large-Part Molding
Sustainability matters when you mold big parts. Material choices affect cost, weight, and what ends up in a landfill. At DeKALB Molded Plastics, recycled resin is a practical way to reduce waste and control cost while still meeting performance targets for large, structural parts.
Why Recycled Resin Belongs in the Conversation
Reintroducing post-industrial and post-consumer plastics back into production lowers demand for virgin resin and diverts material from landfills. It can also stabilize supply and reduce material spend. DeKALB processes millions of pounds of recycled resin each year, so recycled content is not an exception for us. It is a routine option when the application allows.
Why Structural Foam Handles Recycled Resin Well
Not every molding process is friendly to recycled content. Structural foam is.
- Low-pressure fill: The process uses a partial shot and an inert gas or blowing agent to assist flow. Lower cavity pressure is more forgiving of recycled feedstocks.
- Cellular core, solid skin: Parts form a tough outer skin with a foamed interior, delivering a high strength-to-weight ratio. They are three to four times more rigid than solid plastic of the same weight and up to 20% lighter.
- Design latitude: Thick sections, ribbing, and molded-in features reduce secondary operations and help offset natural variation in recycled resins.
The result is durable, dimensionally stable parts that meet spec without over-engineering the bill of material.
What Applications Benefit Most
Recycled content works best where strength, stiffness, and durability matter more than high-polish cosmetics:
- Material handling: Pallets, totes, and rigid bulk containers that see rough duty and long service life.
- Safety products: Guardrail blocks, traffic barrels, and impact-attenuation components.
- Industrial enclosures: Machine covers and housings where stability and wall-thickness control are key.
DeKALB molds parts up to 4′ × 8′ and 30″ deep on presses ranging from 300 to 750 tons, so large footprints and thick sections are in scope for recycled resin strategies.
Materials That Pair Well with Recycled Content
DeKALB can foam nearly any thermoplastic. The following resins are common starting points for recycled content trials:
- HDPE and PP: Workhorses for handling equipment and safety products.
- HIPS and ABS: Good choices for enclosures that need stiffness with reasonable cosmetics.
- PC/ABS and PPO blends: Used when elevated thermal or impact requirements apply.
Our team helps you match resin family, recycled percentage, and reinforcement (glass fiber, glass bead, carbon) to the job.
Engineering Considerations That Keep Quality High
Recycled content still needs to pass engineering muster. We collaborate early on:
- Target percentage by part: Many programs start with 10–30% for first shots, then step up as testing confirms performance.
- Geometry that works for the process: Ribs, bosses, and wall transitions tuned for low pressure reduce sink and warp.
- Qualification and testing: Dimensional layout, mechanical checks, and production-rate trials confirm stability before scale-up.
- Finishing options: When cosmetics matter, our in-house paint shop (including masking, textures, and EMI/RFI shielding) creates consistent surface appearance across recycled content lots.
Sustainability You Can Measure
Choosing recycled resin supports corporate goals and a circular economy. It is also a tangible story: fewer pounds to landfill and a documented reduction in virgin material use. Combined with ISO 9001:2015 quality practices and process controls, the result is sustainable parts that are built to last.
Why DeKALB
Since 1978, DeKALB has focused on structural foam and gas-assist molding for medium-to-large parts. That specialization matters when recycled resin enters the picture. Material selection, mold-flow insights, and low-pressure tooling know-how come together to deliver parts that are strong, stable, and cost-effective.
Takeaways
Recycled resin makes structural foam molding more sustainable and cost-conscious while preserving durability. The process’s low-pressure environment, cellular core design, and wide material compatibility make it especially well-suited for recycled content.
Key benefits for customers include:
- Documented progress toward sustainability goals
- Reduced material costs and waste generation
- Large, rigid parts that meet demanding performance requirements
At DeKALB Molded Plastics, sustainability is integrated into how we mold, engineer, and support every project. Recycled resin is one of the ways we deliver practical results that hold long-term value. Contact us today to explore how recycled resin can support your next project.