Reducing Tooling Costs with Low-Pressure Structural Foam Molding
Tooling decisions carry serious weight in the early stages of product development. For large plastic parts, traditional high-pressure injection molds are expensive, slow to produce, and difficult to revise once they’re in place. That level of investment doesn’t always align with the project’s scale, especially when volumes are moderate or designs may evolve over time.
DeKALB Molded Plastics offers an alternative. Our low-pressure structural foam molding process reduces the cost and complexity of tooling while supporting strong, lightweight, and dimensionally stable parts. It’s a practical path to faster production and better returns.
Read on to see how structural foam molding helps reduce tooling costs from the start.
How Low Pressure Molding Drives Tooling Savings
Structural foam molding relies on an inert gas or chemical blowing agent introduced into the molten plastic before injection. This process creates a cellular core within the molded part while allowing the material to flow through the tool at much lower pressures compared to traditional injection molding. Because there’s less stress placed on the tool, the mold doesn’t need to be built from hardened steel.
Instead, DeKALB uses aluminum tooling that costs significantly less to machine. These tools can be fabricated faster and adapted more easily when design changes are needed. That flexibility is especially valuable for OEMs still refining their product or preparing for future revisions.
Lower cavity pressure also leads to longer tool life in many cases. Although aluminum is a softer material, the reduced force involved in the molding process means wear and tear are minimized. Many customers find that their aluminum tools remain viable across high-volume cycles without the cost or downtime associated with regular maintenance or refurbishment.
Smarter Tooling Strategies
The structural foam process opens the door to a range of tooling strategies that help control costs. When multiple versions of a part are needed, DeKALB can incorporate inserts to support variation without creating entirely new tools. For some projects, secondary machining after molding is the most efficient way to address customization. The right approach depends on the volume, part complexity, and timeline.
Shared molding setups offer another opportunity to reduce cost. When tools have compatible shut heights and use the same material, multiple molds can be run in a single machine. This allows DeKALB to mold different parts during the same production cycle, improving press utilization and lowering the effective cost per part.
These strategies aren’t just about saving money on tooling. They also streamline production and improve responsiveness throughout the entire program, an advantage DeKALB’s customers experience firsthand through our integrated project management support.
Lightweight Parts Without Sacrificing Strength
Lower tooling costs are only part of the structural foam advantage. The process itself delivers strong, rigid parts that are up to 20% lighter than solid molded equivalents. The internal foamed structure creates a high stiffness-to-weight ratio, ideal for applications where durability and dimensional stability are critical.
Wall thicknesses can range from 3/16 inch to 3/8 inch and beyond, with added reinforcement through ribbing where needed. Structural foam is particularly well suited for parts where metal or wood might otherwise be used, offering both strength and weight reduction without excessive material use.
This weight advantage contributes to downstream savings in material costs, shipping expenses, and handling requirements. It also supports sustainability goals, especially when recycled thermoplastics are used – something DeKALB helps facilitate with our extensive materials expertise.
Integrating Value-Added Features into the Mold
With the right tooling approach, it’s possible to reduce or eliminate secondary operations. DeKALB supports molded-in features such as louvers, vents, bosses, and threads. Inserts and fasteners can also be molded directly into the part. These capabilities are built into the tool design, helping to reduce assembly time, labor costs, and the number of vendors required for a complete solution.
When post-mold work is needed, we handle it in-house. That includes painting, bonding, inserting, drilling, kitting, packaging, and more. The full-service model helps maximize the return on every tooling and production dollar by removing handoffs and keeping your project under one roof.
Built for Large Part Programs
DeKALB specializes in medium to large plastic parts, with press capabilities from 300 to 750 tons. Our machines can mold parts up to 4 feet by 8 feet and up to 30 inches deep. We routinely process 3 to 150 pounds of plastic per cycle and work with a wide variety of thermoplastics, including recycled resins and engineered materials.
For OEMs developing plastic housings, safety devices, enclosures, or structural panels, structural foam molding offers a scalable, cost-conscious path forward. Our team brings decades of experience in structural foam and gas assist molding to every project, and our proactive engineering support helps ensure that tooling decisions align with long-term goals.
Make the Most of Your Tooling Budget
High-quality parts shouldn’t require high-cost tooling. DeKALB Molded Plastics helps customers minimize upfront investment without limiting performance, finish, or flexibility. Structural foam molding creates opportunities to reduce part count, simplify tooling, and accelerate timelines.
Planning a new project? Let’s talk. DeKALB can help reduce your tooling costs while delivering durable, high-performance parts that are built to succeed.