Streamlining Design and Reducing Cost in Large-Part Molding
Complex assemblies often start simple: a design split into multiple components to fit tooling, meet strength requirements, or accommodate secondary features. But over time, those extra parts can add cost, complexity, and weight. Structural foam molding offers a smarter path. By combining multiple parts into one, manufacturers can reduce assembly labor, minimize fasteners, and improve overall part performance.
At DeKALB Molded Plastics, part consolidation is a proven way to build efficiency into large, structural products. Our team helps customers simplify their designs, strengthen critical areas, and produce cleaner, more durable parts that perform better and cost less.
Why Consolidating Parts Matters
Each additional part in a design introduces new challenges: alignment tolerances, fastening requirements, sealing surfaces, and potential points of failure. When those parts can be integrated into a single molded piece, those issues go away.
Fewer parts mean:
- Lower labor costs: Assembly time is drastically reduced or eliminated.
- Simplified supply chains: Less purchasing and inventory management.
- Improved quality: Fewer joints, welds, or adhesives that can loosen or degrade.
- Enhanced consistency: Molded-in features ensure each part meets the same dimensional standards.
The result is a stronger, more reliable product that’s easier to manufacture and maintain.
How Structural Foam Supports Integration
Structural foam molding uses a partial shot of molten thermoplastic combined with an inert gas or blowing agent to fill the mold. This low-pressure process allows material to flow evenly into complex cavities that would be difficult — or impossible — to achieve with traditional injection molding.
Because of that flexibility, large, intricate shapes can be molded as a single piece with consistent wall thickness and superior rigidity. The process’s natural cellular core and solid outer skin create a high strength-to-weight ratio, ideal for replacing multi-piece assemblies without adding unnecessary mass.
Structural foam is also less stressful on tooling. Lower pressure means reduced wear, longer mold life, and more design freedom for large, integrated parts.
Built-In Design Advantages
When parts are molded as one, designers have more room to think creatively and functionally. Structural foam supports:
- Molded-in ribs and bosses for structural reinforcement
- Integrated handles, inserts, and brackets that eliminate secondary attachment
- Variable wall thickness for targeted strength and stiffness
- Smooth, continuous surfaces for a professional, finished look
These capabilities reduce the need for adhesives, welding, or fasteners, creating a part that’s not only more durable but also more aesthetically unified.
Applications That Benefit Most
Part consolidation through structural foam molding benefits many large-scale applications, especially in industries where performance and reliability are critical. In material handling, large containers, pallets, and storage systems that once required assembly can now be molded as a single piece, improving durability and reducing weak points under load. Safety products like impact attenuators, guardrail blocks, and barrier systems gain added structural integrity when molded as one component. Industrial equipment, including machine housings, covers, and panels, benefits from smoother geometry, fewer joints, and improved vibration resistance. In utility and construction markets, heavy-duty components, outdoor enclosures, and infrastructure supports hold up better under harsh environments when integration replaces assembly.
Cost and Quality Gains That Add Up
When multiple parts become one, cost savings occur at nearly every stage of production. A single tool replaces several smaller molds, reducing capital expense. Shorter cycle times and less handling improve throughput, while fewer assembly operations lower labor costs and minimize the risk of error. Integrated parts also simplify packaging, shipping, and inventory control. DeKALB’s structural foam process enables manufacturers to achieve these savings without compromising quality or performance. Each part is molded under controlled conditions and inspected for dimensional accuracy to ensure the integrated design delivers strength and stability where it matters most.
Why DeKALB?
Since 1978, DeKALB Molded Plastics has specialized in structural foam and gas assist molding for large, complex parts. This wealth of experience matters when it comes to part consolidation. Our engineers understand how to balance geometry, flow behavior, and material selection to turn multi-part assemblies into single, efficient designs.
Our press range from 300 to 750 tons supports parts up to 4′ × 8′ and 30″ deep, making large-format integration practical. And with in-house finishing, painting, and assembly capabilities, we help customers move directly from mold to market.
Takeaways
Combining multiple parts into one molded piece is one of the most effective ways to reduce cost, strengthen design, and improve manufacturing efficiency. Structural foam molding makes that possible with its low-pressure process, strong cellular structure, and flexibility for large, complex shapes.
Key benefits include:
- Lower assembly and labor costs
- Greater design freedom and part consistency
- Enhanced structural integrity and durability
- Streamlined supply chains and inventory management
DeKALB Molded Plastics helps manufacturers transform complex assemblies into single, high-performing parts that meet cost, strength, and quality targets. Contact us today to discuss how structural foam molding can simplify your next project.