Low-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 […]
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 STORY