Breaking Size Barriers with Structural Foam
When it comes to manufacturing large, complex plastic parts, size and weight limitations often dictate design and production decisions. Traditional molding processes can struggle to balance strength, weight reduction, and cost efficiency, especially for oversized components.
That’s where structural foam molding excels. DeKALB Molded Plastics has spent decades perfecting this process to deliver lightweight, rigid, and cost-effective solutions for large-scale applications across industries. Whether you’re looking to replace heavier materials, optimize production efficiency, or reduce costs, structural foam molding offers an ideal solution.
Let’s dive into how DeKALB’s expertise helps manufacturers push the limits of part size and weight without compromising performance.
Structural Form Parts can be Large
DeKALB’s structural foam molding capabilities provide the precision, durability, and cost control needed for large plastic parts. Our process accommodates dimensions up to 4 feet by 8 feet and 30 inches deep, making it well-suited for oversized components. With machines capable of processing up to 150 pounds of plastic, we can manufacture large, high-strength designs. Ideal wall thicknesses range from 3/16” to 3/8”, with the flexibility to enhance strength through ribbing rather than excess material. These capabilities make structural foam an excellent choice for applications in material handling, industrial equipment, medical enclosures, and more. The process ensures the rigidity and impact resistance required for large-format designs while keeping both weight and costs in check.
Why Structural Foam Molding Is Ideal for Large Parts
When manufacturing large plastic components, striking the right balance between strength, weight, and cost efficiency is essential. Many traditional molding methods struggle to maintain rigidity without excessive material use, leading to heavier parts and higher expenses.
Structural foam molding solves these challenges by delivering lightweight yet durable solutions, making it an excellent choice for oversized applications. The process offers distinct advantages that set it apart from other molding methods, including:
- High Strength-to-Weight Ratio
- 20% lighter than high-pressure molded parts, making handling and installation easier.
- 3-4 times more rigid than solid plastic, improving structural performance.
- Cost Savings Without Compromise
- Lower material costs due to the foamed core structure.
- Lower tooling costs thanks to low-pressure molding, which allows for more affordable aluminum tooling.
- Higher production efficiency, reducing per-unit costs compared to processes like rotational molding, RIM, or die-casting.
- Dimensional Stability & Design Flexibility
- Minimal warp and stress, ensuring consistent part quality.
- Supports complex geometries and integrated features in a single molded part.
- Multi-mold capabilities enable multiple parts to be produced at once, improving efficiency.
- Versatile Material Options
- Compatible with virtually any thermoplastic, allowing for a broad range of application-specific material choices.
- Excellent substrate for high-quality painted finishes, adding visual appeal to functional parts.
How DeKALB Optimizes Structural Foam for Large Parts
While structural foam molding itself is a well-known process, executing it at scale requires the right expertise. At DeKALB, we optimize every aspect to ensure part integrity, efficiency, and cost control:
- Process Engineering for Large Parts Our team ensures optimal flow, cooling, and material distribution, critical for large-scale molding.
- Integrated Reinforcements Instead of adding unnecessary thickness, we design in ribbing and structural supports to maximize strength while keeping weight low.
- End-to-End Project Management From design consultation to final assembly, we work closely with customers to bring cost-effective, high-performance large parts to life.
Where Structural Foam Molding Makes an Impact
DeKALB specializes in large structural foam molded parts, delivering strength, durability, and weight reduction across key industries. Our expertise ensures oversized components meet performance and cost-efficiency requirements in applications such as:
- Medical Housings, Structures & Cabinetry Large, rigid plastic enclosures and panels for hospital beds, MRI helmets, and other medical equipment that require durability and precision.
- Specialty Material Handling Oversized bulk transport containers, rigid storage bins, and pallets designed for shipping food, medical supplies, textiles, and industrial goods.
- Safety Enclosures & Devices Large-scale highway barriers, guardrail blocks, and industrial safety solutions that absorb impact and improve workplace and roadway safety.
Structural foam molding makes large-format plastic parts possible, offering stronger, lighter, and more cost-effective alternatives to traditional materials like metal and wood.
Takeaways
Structural foam molding is not just about making plastic parts – it’s about making large parts better. Manufacturers can achieve size, strength, and weight reduction without compromising durability or cost efficiency. The process expands the possibilities for oversized components across industries, offering an alternative to heavier materials like metal and wood.
DeKALB Molded Plastics has spent decades perfecting this process for large-scale applications. Our expertise helps manufacturers streamline production, reduce costs, and improve part quality. With ISO 9001:2015-certified quality, custom engineering support, and advanced manufacturing capabilities, we provide a turnkey solution for high-performance structural foam components.
Looking for a better way to mold large plastic parts? Contact DeKALB today to discuss how we can help optimize your next project.