Preparing for 2026: Innovations in Structural Foam Molding
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 and production readiness. Read on to see how these updates support better outcomes for the next generation of structural plastics.
Material Advancements Supporting Better Performance
Structural foam already offers clear strength-to-weight advantages for large parts, but performance continues to improve through how resins are formulated and processed. At DeKALB, materials such as HDPE, PP, and engineered blends are commonly paired with additives that enhance stiffness, impact resistance, and dimensional stability based on application requirements.
These material formulations help fine-tune properties like surface quality, shrink behavior, and durability without changing the fundamentals of the structural foam process. Selecting the right resin and additive package early in development plays a key role in reducing risk during design validation and early production builds.
Recycled resin also remains a major priority. As supply consistency and traceability improve, OEMs are increasingly requesting recycled content while maintaining structural performance. DeKALB’s experience processing millions of pounds of recycled material each year allows teams to evaluate recycled options alongside virgin resins and additive systems, supporting sustainability goals without compromising part integrity.
Tooling Strategies That Reduce Cost and Lead Time
Aluminum tooling has long been a differentiator for structural foam molding, and refinements in machining and heat transfer continue to shorten lead times. Faster tool builds, tighter tolerances, and repeatable cooling behavior are helping OEMs launch programs without heavy investment.
Hybrid tooling is gaining traction as well. Steel inserts in high-wear areas extend tool life while keeping overall tooling costs controlled, an important advantage for the low- and medium-volume programs DeKALB supports. These strategies align with what manufacturers are prioritizing for 2026: flexibility, durability, and speed to production.
Smarter Process Controls Strengthening Accuracy and Repeatability
Process control is one of the biggest areas of advancement heading into 2026. More precise shot profiles and improved melt management give teams greater control over foam density and final part appearance, especially on large panels or deep geometries.
Real-time monitoring is another area where OEMs see value. More sensors and data tracking do not change the fundamentals of structural foam, but they make it easier to maintain consistent wall thickness, manage knit lines, and reduce variation from run to run. For projects where repeatability matters, these steady improvements support faster validation and fewer adjustments during early builds.
Gas Assist Applications Expanding Across Industries
Gas assist molding continues to broaden what OEMs can achieve with structural plastics. The process is being applied more frequently to remove sink, reduce weight, and support complex reinforcing structures, all without increasing material use.
Ribs, handles, and deep structural features see clear benefits from gas assist, especially when a cleaner internal surface or reduced cycle time is important. For sectors like material handling, water treatment, and specialty equipment, these advantages support better part performance while reducing secondary operations.
Part Consolidation Driving Simpler, Stronger Assemblies
Part consolidation remains one of the most reliable paths to cost savings, and advancements in both structural foam and gas assist are helping OEMs combine more features into single-piece designs. Fewer fasteners, fewer mating components, and fewer assembly steps all contribute to lower overall cost and improved part strength.
As teams prepare for 2026 launches, many are re-evaluating multi-piece assemblies and identifying opportunities for large-part consolidation. Structural foam’s ability to create rigid, durable components with size and geometry flexibility makes it an ideal fit for that shift.
Sustainability and Lightweighting Becoming Standard Requirements
Sustainability is no longer an optional discussion. It influences material selection, program requirements, and supplier qualification. Structural foam’s inherent density reduction supports lightweighting goals, while recycled resin options reduce material waste and support circularity efforts.
OEMs seeking lighter parts without compromising structural integrity continue to turn toward structural foam for that balance. DeKALB’s experience using recycled materials, optimizing part design, and maintaining long-term durability makes this area a natural fit heading into 2026.
Takeaways
Advancements in materials, tooling, process controls, and gas assist are shaping what structural foam molding will look like as manufacturers prepare for the coming year. These changes are practical, steady improvements that support stronger, lighter, and more economical parts. Combined with DeKALB’s focus on low-pressure molding, aluminum tooling, and value-added services, they give OEMs more flexibility and better long-term performance.
Contact DeKALB Molded Plastics to discuss your next structural foam or gas assist project and explore solutions for your 2026 program.