Industrial 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 […]
VIEW STORYChoosing the best molding process for a plastic part comes down to more than material specs or equipment availability. It’s about aligning performance goals with the right approach to molding. At DeKALB Molded Plastics, two proven methods – gas assist molding and structural foam molding – offer distinct advantages depending on your project’s design, cost, […]
VIEW STORYNot every program calls for hundreds of thousands of parts a year. New product launches, specialty equipment, and replacement components often start with low-to-medium volume expectations. Those programs still need robust parts, but the wrong process can tie up budget in tooling long before production ramps. At DeKALB Molded Plastics, structural foam molding gives OEMs […]
VIEW STORYLaunching a new plastic component should feel organized, predictable, and efficient. That’s exactly how DeKALB Molded Plastics approaches every project. Customers gain a partner that manages the entire journey, from early design through molding, finishing, assembly, packaging, and delivery, so nothing slips through the cracks. Read on to see how DeKALB’s turn-key approach keeps programs […]
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