How DeKALB Delivers Cost-Effective Solutions for Low-Volume Projects
Not 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 another path forward. Our low-pressure process, aluminum tooling, and value-added capabilities help customers make the numbers work on volumes from roughly 100 parts up through steady, medium-volume runs.
Read on to see how DeKALB turns low-volume structural foam projects into cost-effective, production-ready solutions.
Why Low-Volume Projects Need a Different Approach
Traditional injection molding often assumes high volume from the start. Steel tools, high clamp tonnage, and long qualification timelines can make sense for very large programs, but they can push smaller projects out of budget range.
Low-volume and growth-stage programs face different pressures:
- Tooling must be affordable enough to justify the business case.
- Designs may still be evolving through early feedback from the field.
- Part families often include multiple versions or options.
- Schedules are tight, with little appetite for rework or long changeovers.
DeKALB designs structural foam programs around those realities, using a combination of process flexibility, smart tooling strategies, and value-added operations to contain cost while still delivering durable, large-format parts.
Structural Foam: A Strong Fit for Low-to-Medium Volumes
DeKALB’s approach to managing low-to-medium volume production efficiently supports all our customers’ programs. Structural foam molding naturally supports low-to-medium volume production. The process uses a foaming agent in a thermoplastic melt, injected under low pressure to create a part with a solid outer skin and a cellular core. The result is a part that is up to 20% lighter than a solid injection molded part and three to four times more rigid at the same weight.
For OEMs, that combination of low pressure and high stiffness opens up several advantages:
- Lower clamp tonnage and aluminum tooling reduce upfront tool investment.
- Large part capability (up to roughly 4′ x 8′ and 30″ deep, from 3 to 150 pounds) supports housings, enclosures, and material handling products that would be costly in other processes.
- A broad material range including HDPE, PP, ABS, PC, and engineered resins lets our team match performance needs without pushing volumes to unrealistic levels.
Production windows from around 100 pieces to 100,000+ pieces fit well within DeKALB’s structural foam capabilities, so customers can launch with confidence and scale as demand grows.
Lower Tooling Investment Without Sacrificing Part Performance
Tooling is often the largest hurdle in low-volume projects. DeKALB’s low-pressure process allows the use of aluminum tooling instead of large, high-pressure steel molds. That change alone can significantly reduce upfront investment, especially for large parts or assemblies that benefit from multiple cavities.
Because structural foam operates at lower cavity pressure, molds see less wear over time while still producing parts with:
- High stiffness-to-weight ratios
- Low warp and internal stress
- Reliable dimensional stability
For customers, that means tooling budgets stay manageable, yet the parts still deliver the strength and stability demanded in material handling, medical housings, safety devices, and other critical applications.
Part Consolidation That Reduces Total Program Cost
Low-volume projects can’t afford unnecessary complexity. DeKALB’s engineering team looks for opportunities to integrate multiple components into a single structural foam part, eliminating fasteners, brackets, and secondary assemblies.
Structural foam’s design flexibility supports features like:
- Molded-in ribs and bosses for strength
- Louvers, holes, and grilles
- Molded-in threads or inserts
- Integrated mounting and attachment points
Consolidating parts reduces the total number of tools, cuts assembly labor, and simplifies inventory. That combination often brings a low-volume program back into a viable cost range, even when the part design includes demanding mechanical or cosmetic requirements.
Flexible Options for Variants and Design Changes
Low-volume programs frequently include multiple versions of a part: different access panels, mounting patterns, or branding details. They may also evolve as user feedback comes in from the field.
DeKALB supports that reality in several ways:
- Tooling inserts can be used to create variations within a single mold, so customers don’t need a complete new tool for every version.
- Secondary operations such as drilling, routing, welding, and machining allow features to be added or adjusted without redesigning the entire cavity.
- Multi-tool molding lets multiple tools run in the same press when they share material and similar cycle times, improving press utilization and spreading machine costs across multiple part numbers.
Those options give customers maneuverability as their programs grow and change, without resetting the cost structure each time a new variant appears.
Material Flexibility for Specialized Applications
Many low-volume projects serve specialized markets: medical equipment, safety enclosures, or unique material handling products. Those applications often call for specific material properties, flame ratings, or fillers.
DeKALB’s long history with structural foam materials gives customers access to a wide range of thermoplastics and reinforcement systems, including:
- High-density polyethylene (HDPE) and polypropylene (PP) for rugged, impact-resistant parts
- ABS, PC, and PC/ABS blends for balanced strength and aesthetics
- Engineered resin grades for higher load or temperature demands
- Glass fiber, carbon fiber, glass bead, and rubber modifiers for tailored stiffness, impact performance, or weight
That material flexibility means even niche programs can hit mechanical targets, appearance expectations, and regulatory requirements without being forced into volumes that don’t match real demand.
Value-Added Services That Stretch Your Budget
A low-volume structural foam program doesn’t have to stop at molded parts. DeKALB’s value-added operations help customers keep more work under one roof, reducing freight, handling, and coordination costs.
Capabilities include:
- Painting and decorating with solvent and water-based systems, textures, EMI/RFI shielding, and custom masking
- Assembly ranging from simple insert installation to fully assembled, packaged, and ready-to-ship units
- Fabrication and kitting to deliver parts in the exact configuration needed on the customer’s line
With these services integrated into the program, customers often avoid setting up separate vendors or in-house operations for small volumes, which improves overall cost-effectiveness and shortens lead times.
Engineering Support from Concept Through Launch
Cost-effective low-volume production starts well before first shots. DeKALB’s engineering team works directly with OEMs to review designs, recommend structural foam-friendly changes, and select materials that fit both performance and budget.
Support can include:
- Complete part design reviews and optimization
- Mold flow analysis and cooling studies
- Guidance on ribbing, wall thickness, and feature integration
- Tooling and project management from kick-off through PPAP
That upfront collaboration helps keep tooling efficient, reduce trial-and-error, and set up production for consistent results across the life of the program.
Ready to Evaluate a Low-Volume Structural Foam Project?
Low-volume doesn’t have to mean compromise. With structural foam molding, flexible tooling strategies, and a full suite of value-added services, DeKALB Molded Plastics helps manufacturers launch and sustain programs that make financial and technical sense.
If you’re evaluating a new application, looking to convert from fiberglass, metal, or another plastic process, or simply trying to bring tooling costs in line with your forecasted volume, our team is ready to help.
Contact DeKALB today to discuss your low- or medium-volume structural foam project and explore the options that fit your goals.