Experts in Structural Foam Molding - Structural Foam

Structural Foam Molding

At DeKALB Molded Plastics, the push for high-quality processes inspires us to think outside the box and manufacture custom structural foam injection molding solutions. Since 1978, our team has collaborated through team leadership, hands-on experiences, design support assistance, and full concept project management to develop a product that exceeds customer expectations. We work alongside customers to choose the best process for their project, including structural foam molding and gas assist molding. With strong internal resources and innovative ideas, our experienced team takes on the challenge of delivering turn-key product solutions.

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How Does The Structural Foam Process Work?

The structural foam process allows the production of rigid, molded plastics which have a cellular foamed core surrounded by an outer skin, forming a total integral structure. Products molded with the structural foam injection molding process have a high strength-to-weight ratio and are 3 to 4 times more rigid than solid parts of the same weight.

Before injection into the tool, inert gas is introduced into the melt.

Only a partial shot is used because, along with the low machine pressure, the gas creates a foaming action that helps the flow, fill, and pack of the mold.

The plastic cells collapse as they encounter the wall of the mold, creating the solid plastic skin. The foaming action continues to push the leading edges of the melt into the furthest extremes of the mold.

Once the mold is completely packed out and begins to cool the ‘frozen’ outer skin becomes solid and rigid. The inner core develops a cellular or honeycomb structure when cooled.