The Role of Structural Foam Molding in Safety Products
Protecting lives in high-risk environments – on the road, in industrial facilities, or during emergency response – requires more than metal barriers and warning signs. Behind the scenes, molded safety products like impact attenuators, guardrail blocks, and protective equipment cases help reduce injury, prevent accidents, and keep people safer under demanding conditions. At the heart of many of these solutions is structural foam molding, a process that blends strength, efficiency, and design flexibility.
DeKALB Molded Plastics has been producing molded safety products since 1978. With decades of experience and a clear focus on structural foam technology, we help transportation, industrial, and emergency response teams bring reliable, high-performing components to market, all while keeping costs in check.
Read on to explore how structural foam molding supports safety across a range of applications and why DeKALB’s approach makes the difference.
Why Structural Foam Molding Works for Safety Applications
Creating safety products that are both strong and lightweight is no small task. Structural foam molding strikes this balance by injecting a foaming agent into a polymer melt, forming a cellular core surrounded by a solid outer skin. The result? A molded part that’s up to four times stiffer than solid plastic and approximately 20% lighter.
That lighter weight provides major real-world advantages: faster installation, lower shipping costs, and less physical strain for crews. Meanwhile, the stiff, durable outer skin withstands physical impacts and environmental extremes, ideal for parts exposed to heat, cold, moisture, or UV radiation.
Thanks to the low-pressure nature of structural foam molding, oversized parts can be produced cost-effectively with lower tooling investment. This opens the door for large-format safety components like impact attenuators, guardrail blocks, and rugged protective cases designed to meet precise performance requirements.
Impact Attenuators: Absorbing Energy When It Counts
Also known as crash cushions, impact attenuators are designed to absorb the energy of a high-speed collision and minimize harm to drivers and passengers. Positioned along highways, in construction zones, or at hazard-prone intersections, these safety devices provide a critical buffer between vehicles and fixed roadside objects.
At DeKALB, structural foam molding is the preferred process for producing these life-saving tools. The foamed core dissipates impact energy, while the solid outer layer maintains shape and integrity. Each unit is molded to tight tolerances to support consistent field performance.
Installation is simplified thanks to reduced weight, making it easier for crews to place and secure impact attenuators even under tight timelines or in difficult conditions.
Rethinking Guardrail Blocks
Guardrail blocks serve a key function in roadside safety by maintaining the proper spacing between rails and posts to absorb crash energy and prevent vehicle underride. Traditional options like wood or metal can splinter, rust, warp, or vary in size, which leads to performance gaps and ongoing maintenance.
Foam-molded blocks eliminate these issues. DeKALB’s structural foam guardrail blocks are dimensionally consistent, moisture-resistant, and built to last in harsh outdoor environments. They stand up to UV rays, temperature swings, and long-term physical stress without cracking, rotting, or requiring frequent replacement.
Design flexibility is another major plus. Molded-in features like slots, mounting points, or reinforcements can be built directly into the part. Multi-cavity tooling allows multiple blocks to be produced in a single cycle, reducing lead times and improving production efficiency.
The result? A better-performing guardrail system, with fewer headaches and better ROI for municipalities and contractors alike.
Protective Equipment Cases for Emergency Response
Structural foam molding doesn’t just improve roadside safety; it also supports critical emergency gear protection. DeKALB manufactures protective wall cases used to house equipment like Self-Contained Breathing Apparatus (SCBA) systems, commonly deployed in fire stations, chemical facilities, and hazardous response units.
These wall-mounted cases must perform in the most demanding conditions. Our chemical-resistant structural foam enclosures are built to withstand impacts, exposure to corrosive agents, and extreme environmental changes. The rigid outer skin offers reliable protection, while the molded construction allows for integrated latches, seals, and secure mounting features.
In addition to SCBA gear, these cases are suitable for protecting a wide range of emergency safety products by delivering lightweight durability without compromising on strength or functionality.
Performance That Stands the Test
No matter the application – on a highway, at an industrial site, or on the wall of a fire station – molded safety products must endure unpredictable and often extreme environments. From freezing rain to blazing heat, each component must perform under pressure.
DeKALB’s structural foam parts meet that challenge. The cellular interior resists deformation, while the solid exterior stands firm against weather, salt, UV exposure, and debris. For parts that require thick walls or detailed internal features, gas-assist molding can be used to form hollow sections that reduce material use and weight without sacrificing durability.
The result: Fewer replacements. Lower maintenance. More consistent safety performance.
A Proven Safety Partner
There’s a reason public safety agencies and OEMs continue to partner with DeKALB. With a full understanding of both processing and performance demands, we deliver end-to-end support, from concept to delivery.
Strict process control, internal testing, and value-added services like painting, fabrication, sonic welding, and packaging make us a true single-source partner for safety components. Instead of juggling multiple vendors, customers benefit from streamlined communication, consistent results, and the peace of mind that comes with proven experience.
Molded for Safety. Built to Last.
As safety needs evolve and expectations rise, structural foam molding offers the perfect combination of durability, weight savings, and design freedom. From impact attenuators and guardrail blocks to protective equipment cases, DeKALB continues to support essential safety applications with precision, reliability, and purpose.
Looking for a partner who understands the demands of real-world safety? Connect with DeKALB to explore how our structural foam molding expertise can support your next project.