Large, durable parts don’t always have to be made from metal. Structural foam molded products often deliver adequate rigidity, stability, and strength industrial teams expect from die-casting, often with lower costs, lighter weight, and greater design flexibility. At DeKALB Molded Plastics, we’ve seen many customers successfully transition from aluminum or zinc die-casting to structural foam […]
VIEW STORYLarge plastic parts face a tough challenge: they need to be strong and stable, but they also must look good. Thick walls can cause sink marks, uneven surfaces, and warpage. Traditional molding methods often struggle with those issues, which leads to extra work and extra cost. That’s where gas assist molding makes a difference. By […]
VIEW STORYLarge equipment calls for dependable, long-lasting parts that can take a beating. In industries like construction and heavy machinery manufacturing, every component must handle constant vibration, extreme temperatures, and repeated impact while keeping weight and cost under control. Structural foam molding helps achieve that balance, offering the strength of metal with the design freedom and […]
VIEW STORYComplex assemblies often start simple: a design split into multiple components to fit tooling, meet strength requirements, or accommodate secondary features. But over time, those extra parts can add cost, complexity, and weight. Structural foam molding offers a smarter path. By combining multiple parts into one, manufacturers can reduce assembly labor, minimize fasteners, and improve […]
VIEW STORYIn medical manufacturing, reliability is not optional. Every housing, frame, and enclosure must meet precise specifications and perform the same way every time it’s used. Structural foam molding offers a way to create large, complex plastic parts that hold up to demanding conditions. At DeKALB Molded Plastics, we’ve been perfecting the process for decades. Our […]
VIEW STORYNot every plastic part needs to be heavy to be strong. When performance, weight, and cost all matter, structural foam molding offers a smart, proven solution. DeKALB Molded Plastics has spent decades helping manufacturers build large plastic parts that hold up under pressure without adding unnecessary bulk. Read on to see how the structure of […]
VIEW STORYBuilding Sustainability into Large-Part Molding Sustainability matters when you mold big parts. Material choices affect cost, weight, and what ends up in a landfill. At DeKALB Molded Plastics, recycled resin is a practical way to reduce waste and control cost while still meeting performance targets for large, structural parts. Why Recycled Resin Belongs in the […]
VIEW STORYPlastic parts built for demanding environments often require more than structural integrity; they also need to look the part. At DeKALB Molded Plastics, painting is an integral part of our value-added manufacturing approach, designed to help customers achieve both performance and aesthetics in one streamlined process. From visual branding to protective finishes, in-house painting allows […]
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