Gas Assist Molding for Aesthetic and Functional Excellence
Large plastic parts face a tough challenge: they need to be strong and stable, but they also must look good. Thick walls can cause sink marks, uneven surfaces, and warpage. Traditional molding methods often struggle with those issues, which leads to extra work and extra cost.
That’s where gas assist molding makes a difference. By introducing pressurized gas into the molding process, we can produce lighter parts with smoother surfaces and consistent strength. At DeKALB Molded Plastics, gas assist molding is one of the tools we’ve refined over decades to help customers bring complex, large-scale parts to market with confidence.
How Gas Assist Molding Works
The process starts with molten resin injected into the mold, but only partway. Then, nitrogen gas is introduced into the thickest sections of the part. That gas pushes the plastic into corners and tough-to-fill areas, forming hollow channels as the material cools.
DeKALB uses Milacron Structural Web Gas Assist and Bauer Gas Assist technologies to achieve precise, reliable results. The resin and gas never mix; instead, the gas displaces the resin into the thicker wall sections and keeps pressure steady while the part cools. The result is a part that’s free of common surface flaws, with less stress locked inside.
In short, it’s a way to mold large, durable parts that look sharp and hold their shape.
Appearance That Matches Performance
Parts molded with gas assist have noticeably improved surface characteristics. The process minimizes sink marks, knit lines, and other visible flow imperfections, resulting in a uniform, high-quality finish. Many parts come out of the mold with surfaces smooth enough for use without secondary finishing.
Applications like machine covers, enclosures, or consumer-facing panels benefit from this level of detail. Gas assist molding provides the visual consistency and dimensional stability these parts need to meet performance requirements while maintaining a professional appearance.
Functional Advantages
Gas assist molding does more than improve appearance. Hollow gas channels cut down on part weight while maintaining stiffness. The way the resin flows under pressure reduces warpage and distortion, which helps complex parts fit together the way they’re supposed to.
Other key advantages include:
- Design flexibility: Thick and thin wall sections can be molded together more easily.
- Strength with less weight: Hollow channels provide rigidity without solid plastic throughout.
- Efficiency in the press: Lower cavity pressure means smaller presses can run larger parts.
- Faster cycles: Reduced cooling times keep production moving.
- Repeatable results: Parts come out consistent, run after run.
Those benefits mean less material waste, shorter lead times, and more reliable performance in the field.
Built for Complex Applications
Gas assist molding is a natural fit for large, intricate parts. We’ve applied it to everything from door handles and machine housings to safety enclosures and protective covers. These are parts that not only need to be durable but also present well in front of customers.
By combining lightweight strength with a clean finish, gas assist gives manufacturers an edge in balancing function and appearance.
Why DeKALB Molded Plastics
DeKALB has specialized in structural foam and gas assist molding for decades. That focus allows us to tackle projects where other processes, or other suppliers, may struggle. Our customers rely on us for parts that are big, durable, and ready for real-world use.
We bring proven technologies and a team that understands how to apply them. Projects start with early collaboration, where we review designs, materials, and goals with customers to see if gas assist is the right fit. From there, we optimize the process to balance cost, performance, and appearance.
Because we also offer painting, assembly, and packaging in-house, customers don’t have to ship parts out to multiple vendors. A machine cover, for example, can move straight from our molding press to the paint line, through assembly, and onto a truck — all without leaving our facility. That integrated approach reduces risk, saves time, and keeps quality under one roof.
Takeaways
Gas assist molding gives manufacturers a reliable way to produce parts that are lighter, smoother, and structurally sound. The process cuts cycle times, reduces defects, and supports complex designs, all while delivering the appearance customers expect.
At DeKALB Molded Plastics, we combine decades of experience with proven gas assist technologies to deliver parts that look professional, perform consistently, and add measurable value to your program.
Looking for a partner who can bring both performance and precision to your molded parts? Contact us today to learn how gas assist molding can support your next project.