Applications of Structural Foam in the Medical Device Industry
In medical manufacturing, reliability is not optional. Every housing, frame, and enclosure must meet precise specifications and perform the same way every time it’s used. Structural foam molding offers a way to create large, complex plastic parts that hold up to demanding conditions. At DeKALB Molded Plastics, we’ve been perfecting the process for decades.
Our team works side by side with medical OEMs to produce components that integrate seamlessly into critical devices. That partnership often starts well before tooling is built, with conversations about how a part will be used, what safety requirements it must meet, and how it needs to perform in the field. From that foundation, we help customers choose the right materials, refine designs for manufacturability, and bring dependable parts into production.
Read on to see how structural foam supports real-world medical applications and why OEMs trust DeKALB to deliver.
Precision That Meets Medical Standards
Medical devices are often designed around tight tolerances. Even a small shift in alignment can affect performance, especially in diagnostic equipment where accuracy is essential. Structural foam molding is well suited to these needs. Its low-pressure process reduces molded-in stresses, helping parts stay dimensionally stable over time. That stability means fewer issues with warping or distortion, even after repeated cleaning cycles and years of service.
At DeKALB, we take the time to review each design in detail before production begins. CAD models and mold flow analyses help us identify potential concerns early, so adjustments can be made before a tool is cut. That upfront attention reduces risk, saves time, and results in components that meet the exact needs of each device.
How Structural Foam Shows Up in the Medical Field
The versatility of structural foam molding makes it a strong fit for many different medical products. Over the years, we’ve helped customers develop:
- Electrical and hospital bed components: Lightweight, rigid frames and supports that withstand heavy use and allow for easier maneuvering.
- MRI helmets: Rigid shells that keep their shape to support accurate brain imaging, designed with patient comfort in mind.
- Ultrasound and bone densitometer housings: Stable, protective enclosures for sensitive diagnostic equipment.
- Dialysis equipment cabinetry: Durable panels and structures that stand up to frequent handling and cleaning.
- Blood analyzer housings: Precision-molded parts that protect complex internal systems.
- Medical carts: Mobile units built to hold and transport equipment safely in fast-paced environments.
Each of these projects required not only the benefits of structural foam but also DeKALB’s ability to adapt the process to specific requirements, from part geometry and wall thickness to surface finish and paint compatibility.
What the Process Delivers for OEMs
Structural foam molding offers more than one type of advantage, and in the medical industry, those advantages often work together to solve both performance and cost challenges. For example:
- Weight and strength in balance: Structural foam parts are up to 20% lighter than high-pressure molded parts while remaining several times more rigid than solid plastic.
- Tooling flexibility: Lower mold cavity pressures make it possible to produce large parts or multiple parts in a single cycle, reducing overall tooling investment.
- Design versatility: Capable of molding parts as thin as 0.156″ or with much thicker load-bearing sections, allowing engineers to match the part to the function.
- Dimensional stability: Maintains precision over long-term use, even under mechanical or environmental stress.
- Surface readiness: Paintable finishes that meet the visual and hygiene requirements of medical equipment.
These capabilities give OEMs the freedom to design for performance without overspending on tooling or sacrificing production efficiency.
Why DeKALB Is the Right Fit for Medical Projects
Since 1978, we’ve built structural foam parts for industries where performance is critical. Our medical work benefits from the same disciplined approach we apply to other high-requirement markets: clear communication, careful planning, and a deep understanding of how each part will be used.
Structural foam molding adapts well to changing requirements. In medical applications, that can mean meeting updated safety standards for equipment like medical carts or maintaining precise geometry in MRI helmets. Our process supports both needs through careful material selection, thorough design review, and tooling built for consistent, repeatable results.
That combination of technical expertise and real-world application knowledge is what sets our work apart. We don’t just mold parts. We create components that help medical devices function reliably in the environments where they matter most.
Start Your Next Medical Project with DeKALB
The right manufacturing partner can make the difference between a component that works in theory and one that performs flawlessly in the field. Contact DeKALB to learn how our structural foam molding capabilities can support your medical device application from concept to production.