Choosing the right molding process starts with the part itself. Some applications call for small, highly cosmetic parts made under high pressure, while others need larger components, better rigidity, lower tooling costs, or a manufacturing approach that supports finishing and assembly after molding. When those priorities start to define the project, structural foam molding often […]
VIEW STORYMolded plastic enclosures often do more than cover internal components. In many industrial applications, they need to protect and support hardware, resist impact, hold their shape, and maintain a clean appearance. Once those requirements start stacking up, enclosure design becomes a structural challenge rather than a simple housing decision. Part size tends to bring more […]
VIEW STORYAmerican-made manufacturing still matters for OEMs because it puts control back where it belongs: closer to the teams responsible for performance, timelines, and product launches. Long-distance supply chains can work for certain programs, but many OEMs have learned that distance often adds friction: lead times stretch; communication slows down; changes take longer to implement. For […]
VIEW STORYIndustrial components are under constant pressure to perform. Large housings, bases, and enclosures must carry load, resist impact, and hold dimensional tolerances over years of use. At the same time, added mass can create downstream challenges in handling, shipping, and assembly. Structural foam molding offers a practical way to increase stiffness and durability without adding […]
VIEW STORYA CAD file may look complete on screen, but production readiness is another story. Geometry, material behavior, tooling strategy, and long-term performance all influence whether a part performs the way it was intended. In structural foam and gas assist molding, those considerations matter even more. As a company, DeKALB is focused on accountability, collaboration, and […]
VIEW STORYMaterial choice influences nearly every aspect of a molded part, from structural strength to cosmetic finish. For structural foam and gas assist molding, selecting the right thermoplastic is essential to getting the most from the process. Each resin behaves differently under pressure, heat, and flow conditions, which means material decisions must be grounded in performance, […]
VIEW STORYTooling 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. […]
VIEW STORYLow-pressure structural foam molding continues to evolve as OEM expectations shift toward stronger, lighter, and more cost-effective large parts. Advances in materials, smarter tooling strategies, and enhanced process controls are shaping the way teams plan programs for 2026. Structural foam and gas assist are both seeing steady, practical advancements, especially in areas tied to efficiency […]
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