Material 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 […]
VIEW STORYLarge, 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 […]
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