10 Questions You Should to Know about structural foam molding

Just as with high-pressure molding, a top-quality tool-maker will serve the manufacturing company well when designing, building and testing your molds.

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Important considerations when designing your parts and tools.

Critical considerations when designing a part and tool for any plastic injection molding and special factors for structural foam include the following:

First of all, structural foam is a process, not a specific material. In general, structural foam increases the compressive strength and flexural modulus versus solid plastic. Impact strength and tensile strength can have a slight reduction.

Dimensionally, we can produce parts up to 4’ x 8’ and 30” deep. We have machines that hold 150 lbs of plastic, so we can produce some very large parts.

Thickness ranges from 3/16” to 3/8” (4.7mm to 10mm). We can go thicker, but usually find it to be more cost effective to add strength with ribbing rather than thicker sections of plastic.

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We can mold almost all thermoplastics. For instance, we currently have projects using HDPE, PP, PS, ABS, PPO, PC and work with engineered resin for structural foam too. Let us know what you need – we are up to the challenge!

This is very common. We can either build inserts for the tool to produce the variations or we can machine (drill/cut/router/weld) the variation. Your volume levels drive the most cost-effective solution.

We can mold in threads. We can also add brass inserts for 8-32, 10-32, and ¼-20 threads (and M4, M5, M6). We have even put Tee nuts from woodworking into some softer plastics.

Our process requires less pressure than standard injection molding. We typically use aluminum tooling, which is less expensive compared to a similar size standard injection (steel) tool.

It is true. The tool has to have the same shut height, use the same material, and operate at about the same run rate. This will reduce both your production time and cost.

Contact us to discuss your requirements of custom plastic injection molding. Our experienced sales team can help you identify the options that best suit your needs.