Plastics Fabrication Services: How We Make Sure Your Products Are Exactly as You Imagine

Plastics Fabrication Services: How We Make Sure Your Products Are Exactly as You Imagine

Plastics fabrication services ensure that your products are exactly as you imagine before heading to the end consumer. Various services can be performed after the production of your product to make this happen. From assembly and welding to drilling and fastening and more, plastic fabrication is an integral part of your part production.

In this blog, we will focus on the different types of plastic fabrication services and how they can benefit your projects in the long run.

Types of Plastics Fabrication Services

There are many types of plastics fabrication services out there, however, we are going to review some of the common services offered at Port Erie Plastics.

Assembly

One of the most common types of plastic fabrication services out there is assembly. This means your products will arrive to their final consumer fully put together so it is immediately ready for use. Assembly services include fab assembly, kitting, and bag pack-outs.

Adding Components

Fabrication services also include adding components. These components can be used to put products together or assist with functionality. At Port Erie Plastics, our team has the ability to add aluminum extrusions, screws, nuts, fasteners, Velcro strips, spindles, latches, springs, and rods.

Drilling, Welding, and Fastening

At Port Erie, we are able to join plastic products together in a variety of ways, including:

• Drilling: Our team can drill holes for fasteners to join plastic parts together and for other functional purposes.

• Welding: We have various welding capabilities to join your plastic parts together, including heat, ultrasonic welding, and adhesive welding.

• Heat Staking: This process utilizes pulsed heat to join two or more plastic parts together.

Secondary Operations

Other fabrication services include secondary operations. These processes include decorating, assembly, pad printing, heat transfer, hot stamping, packaging, distribution, and warehousing.

Benefits of Plastic Fabrication Services

Improve Aesthetics

Plastic fabrication services improve the look and feel of your products. These services ensure that your products have smooth edges, are assembled correctly, and are decorated exactly as you imagine.

Improve Tolerances

These services ensure that the tolerances of your products are met. From trimming down edges slightly to properly putting products together, and more, these services make it easy for your products to meet the requirements of their application and the industry.

Improve Safety

Fabrication services can also help improve the safety of your products. Whether you are improving the finishes of your products to make them smoother or adding textures to your products, you can make them easier to use or easier to grip, thus improving the safety of your product.

Want to Know More About Our Plastics Fabrication Services? Contact Port Erie Today

Since 1953, Port Erie Plastics has been a trusted manufacturer of plastic injection molded and structural foam molded products. While providing these manufacturing services, we also offer a wide range of fabrication services to ensure that your product meets the specifications of your industry.

After your products are finished, our team is also able to warehouse them for you until they are ready to be shipped. And, if you need assistance with distribution, our team is ready to help there as well.

Contact our team to see what we can do for you.

Manufacturing Structural Foam and Injection Molding Tooling: Controlling Quality From the Start

Manufacturing Structural Foam and Injection Molding Tooling: Controlling Quality From the Start

When you are choosing a plastic injection molding or structural foam molding partner, it is important to ensure they have in-house tooling capabilities. This allows your manufacturer to design and create your structural foam and injection molds, ensuring that they are exactly what your project needs and of the highest quality possible.

Continue reading to learn more about how you can benefit from in-house tooling and what the process looks like when you partner with Port Erie Plastics.

Why is In-House Tooling Better Than Outsourcing?

When your structural foam or injection molding tooling is made in-house, you don’t have to worry about the hassle or the cost of finding a different company to take on your tooling projects. This means you won’t have to worry about shipping your molds from one manufacturer to another, saving you money and reducing the lead times on your projects.

Additionally, our team has full control over the quality of your molds, allowing us to make any necessary adjustments before we start production. This saves you the time and money required to send molds back and forth to make adjustments before production. Plus, if there are any issues during production, our team can make the necessary changes and repairs to the molds in-house.

How Your Structural Foam and Injection Molding Tooling is Created

At Port Erie Plastics, each project is assigned a plastics engineer who will review your product design to ensure there are no concerns. This process includes a Design for Manufacturability review. During this process, the plastics engineer will review the design of your product and molds to ensure that the product can be efficiently manufactured via your chosen process.

Once the design review takes place, your molds can be manufactured in our in-house, full-service tool room. We have various capabilities that allow us to create the tooling you need, including CNC milling, grinding, turning, drilling, welding, and more. Some of the types of molds we create include:

• Single cavity
• Multi-cavity
• Structural foam molds
• Insert molds
• Over molds
• Hot runners

We also create our molds from P-20 tool steel, stainless steel, hardened steel, or aluminum, ensuring that your injection molding tooling will last for the duration of your project.

In addition to our mold manufacturing services, we also offer tooling transfer services. During this process, you will transfer your existing molds to our facility. Our team will inspect the tooling, identifying any potential problems with the design or any damage to the mold. We will use our in-house tooling capabilities to make the necessary repairs and changes. Then, our team will complete verification testing of the tooling to ensure it is up to our standards and ready for use in production.

When You Need Quality Structural Foam and Injection Molding Tooling, Partner with Port Erie Plastics

At Port Erie Plastics, our team is dedicated to creating high-quality injection molds and structural foam molds to ensure your plastic products are of the highest quality and meet all of your expectations.

In addition to our in-house tooling capabilities, we can also produce the products you need. We have both injection molding and structural foam molding manufacturing capabilities. This allows us to take on large-tonnage plastic projects with ease, as our structural foam molding capabilities are ideal for creating these larger products.

After production, our team has the ability to assemble, decorate, and fabricate your products. This includes drilling holes, welding inserts, pad print, heat transfer, and more. Then, you will have the option to warehouse your products with us and have our team assist with the distribution of your products if you so choose.

Contact our team today to learn more, or to get started.

Collaborative Robots for Plastic Production: How Automation Has Improved

Collaborative Robots for Plastic Production: How Automation Has Improved 

Automation has been making its way into nearly every industry over the last few years, and the plastic injection and structural foam molding industries are no different. The implementation of collaborative robots for plastic production has offered many benefits, including reduced error in production and more efficient production. Let’s explore what collaborative robots are and how they have improved many plastic production processes.

What are Collaborative Robots for Plastic Production?

Collaborative robots, also known as cobots, are industrial robots that safely operate alongside humans in a shared workspace. These robots use mobile technology, AI, machine vision, cognitive computing, and touch technology to perform various tasks safely in close proximity to human workers. They are equipped with software-controlled sensors that give them the ability to detect objects, people, and collisions.

What Do Collaborative Robots Do For Plastic Production?

Collaborative robots can do many things to ensure processes run smoothly and safely while reducing human error. Some common applications of collaborative robots for plastic production include:

• Loading and unloading polymers, materials, and parts
• Quality control by orienting parts and utilizing sensors to determine if there are any dimensional errors
• Assembling, sorting, and stacking, including welding to build assemblies and arranging parts for kitting or packaging
• Secondary processes such as decorating and labeling

Benefits of Collaborative Robots in Plastic Manufacturing Processes

Rapid Production

Automated machinery works faster and longer than human workers in many processes. This allows the machines to create more products in a shorter timeline, and they can work longer hours to meet demand faster than traditional manufacturing methods.

Reduced Costs

Utilizing automated processes reduces the risk of error in the production processes, including fewer mistakes, less warpage, and less damage. Additionally, automated robots can take the place of human employees, reducing the cost of labor, and manufacturers can pass these savings on to their customers.

Improved Sustainability

Since automated machines produce parts and products with fewer errors, there is no need to rerun production processes, reducing the amount of inaccurate or warped products. Additionally, with improved fabrication efficiency, less energy can be used during production. Overall, the process reduces the amount of waste produced and energy used during the manufacturing process.

If You Are Interested in Using Collaborative Robots for Plastic Production, Contact Port Erie Plastics

Since 1953, Port Erie Plastics has been providing high-quality structural foam molded and injection molded products to customers in a wide range of industries. Not only do we provide traditional manufacturing services, but we also offer automated injection molding services to streamline your manufacturing.

When you partner with us, our team will match you with one of our skilled plastics engineers to help ensure your products are properly designed for the manufacturing process you choose. We will then create your tools and molds with our in-house tooling capabilities and begin manufacturing your products.

Once your products are created, we offer secondary operations, including assembly, decorating, fabrication, welding, and more. Then, our team can warehouse your products for you based on your timeline and can even help with distribution.

Contact our team today to learn more about what we can do for your projects.

How Do You Mold Large Plastic Parts?: The Structural Foam Molding Process and Advantages

How Do You Mold Large Plastic Parts?: The Structural Foam Molding Process and Advantages

Large plastic parts and products are needed in many industries, including construction, consumer goods material handling, and more. Unfortunately, finding the right manufacturing processes to create large plastic parts can be difficult. Many times, creating these parts is expensive, and time-consuming, and you run the risk of having issues with deformities. So, how do you mold large plastic parts and products? One of the best ways is through structural foam molding. Continue on to learn more about the process and its advantages.

The Structural Foam Molding Process

The Manufacturing Process

The structural foam molding process begins with mixing a melted polymer with nitrogen gas and/or a chemical blowing agent. This mixture is then injected into the structural foam mold under low pressure. The polymer mix will touch the walls of the mold and cool, forming a product with a solid exterior and honeycomb interior. The result is a large, complex product with a durable exterior layer and a less dense inner layer, reducing its weight compared to its injection molded counterparts.

Plastics Used in the Structural Foam Molding Process

Polyethylene is the most common plastic used in the structural foam molding process. This polymer is resistant to chemicals and water, is recyclable, has a high strength-to-weight ratio, low moisture absorption, high impact strength, and is durable. However, polyethylene does have poor weather resistance, is flammable, and can be sensitive to stress cracking. Polyethylene is used to create chemical containers, pipe systems, gardening equipment, and more.

Benefits of Structural Foam Molding

Create Large Parts Easily

The low-pressure process requires less clamping force which allows you to create tooling and molds from more cost-effective materials, such as aluminum. This low-pressure process also leads to less damage, reducing the cost and time spent on rerunning projects.

Design Flexibility and Reduced Risk of Warpage

Again, the low-pressure process puts less stress on the product, so it doesn’t experience as much damage as parts that are produced through straight injection molding. This reduced risk of warpage allows you to create more complex molds that maintain the desired shape of the finished product.

Efficiency

Multiple structural foam molds can be run at the same time. The low-pressure process allows molds to run simultaneously without putting stress on the machines and the models, saving you time and money in your manufacturing process.

Desirable Physical Properties

Structural foam molded products have many desirable properties, including a high strength-to-weight ratio, good thermal stability, durability, chemical resistance, and more.

Structural Foam Molding Applications

Numerous industries use structural foam molding to create their products. Port Erie has been lucky enough to partner with many companies to manufacture the large tonnage plastic products they need, including HDPE trench drains, garden carts, lawn equipment, and pallets. Learn more about the products created through structural foam molding by viewing our blog.

Ready to Learn How You Mold Large Plastic Parts? Contact Port Erie Plastics

At Port Erie, we have been creating plastic products through structural foam molding and injection molding since 1953. Not only do we have the capabilities to create your products, but we take quality into account from the very start by offering in-house tooling and mold design. Plus, our team also assigns a skilled plastics engineer to each project to ensure your products are of the highest quality and designed for efficient manufacturing.

Contact our team today to learn more.

Exploring the Common Types of Plastic for Injection Molding and Structural Foam Molding

Exploring the Common Types of Plastic for Injection Molding and Structural Foam Molding

Injection molding and structural foam molding are essential manufacturing processes with distinct advantages in production speed, cost-effectiveness, and design versatility. But with the range of plastics available, selecting the right material for your project can feel like a big task. Different polymers offer unique characteristics that can enhance the durability, flexibility, and overall performance of your products. Here, we’ll break down the most common types of plastics for injection molding and structural foam molding, highlighting their strengths and applications.

Types of Plastic for Injection Molding

ABS

ABS is another common type of plastic for injection molding. It’s a versatile choice that is used widely across industries for products like toys, electronic housings, tools, and construction equipment. Known for its impressive impact resistance and rigidity, ABS can withstand rough handling and extreme temperatures, making it ideal for applications requiring durable and long-lasting components. Plus, its easy machinability means it’s well-suited for projects that need detailed designs.

HDPE

Next on our list of the common types of plastic for injection molding is HDPE (High-Density Polyethylene). This material is often chosen for storage containers and consumer goods due to its chemical and heat resistance, affordability, and recyclability. As a 100% recyclable material, HDPE is also an environmentally conscious choice that doesn’t compromise on strength or longevity. If you’re designing products that demand durability at a low cost, HDPE is a fantastic option.

Polycarbonate

Polycarbonate is one of the types of plastic for injection molding that is popular in applications like piping and consumer goods, thanks to its robust impact resistance, UV stability, and chemical resistance. This polymer offers the rigidity needed for high-performance applications where components must withstand physical stress and environmental exposure without deformation or degradation over time.

Polypropylene

Finally, polypropylene is a plastic that brings elasticity, fatigue resistance, and electrical insulation to the table, making it an excellent material for storage containers and various consumer goods. As another common type of plastic for injection molding, its chemical resistance adds to its durability, making polypropylene suitable for items that need to retain structural integrity under repeated bending or exposure to harsh conditions.

Types of Plastic for Structural Foam Molding

Polyethylene

For structural foam molding, polyethylene is frequently used in piping systems, chemical tanks, and other applications where lightweight yet durable materials are necessary. Polyethylene’s chemical and impact resistance, combined with its non-absorbent qualities, makes it an ideal choice for environments exposed to moisture and chemicals. Additionally, its dielectric properties ensure it’s safe for electrical insulation applications.

Polypropylene

Lightweight, durable, and corrosion-resistant, polypropylene is widely used for machinery parts and customer appliances that must perform reliably under constant use. Its high resistance to fatigue and chemicals ensures that polypropylene components retain their shape and functionality over time, making it a preferred choice for structural foam molding projects requiring longevity and resilience.

Unsure What Types of Plastic for Injection Molding are Best for Your Project? Port Erie is Here to Help

With an extensive selection of materials and decades of expertise, Port Erie’s team is ready to assist you in finding the perfect polymer for your injection or structural foam molding project. Our engineers are well-versed in the unique properties of each material and can provide detailed guidance to match your product requirements with the ideal plastic, ensuring the best performance and cost-effectiveness for your applications.

At Port Erie, we also offer comprehensive support, from material selection and design consultation to in-house tooling, manufacturing, and post-production services like kitting, assembly, and decorating. Our warehousing and distribution services, which include multiple storage facilities and just-in-time delivery options, further streamline your production and logistics processes so you can focus on growing your business.

Contact our team today to discuss how we can support your project and guide you in choosing the best materials for injection or structural foam molding. Whether you’re navigating complex design requirements or need a full-service manufacturing partner, Port Erie has the experience, capabilities, and dedication to make your project a success.

Plastics Distribution and Logistics: Another Way Your Manufacturer Can Assist You

Plastics Distribution and Logistics: Another Way Your Manufacturer Can Assist You

Navigating plastic distribution and logistics can be complex, especially when you’re managing other areas of your business. Fortunately, an experienced plastic manufacturer can streamline the process. When you trust your manufacturing partner to handle plastics distribution and logistics — things like storage, fulfillment, and delivery — you can stay focused on your priorities. Let’s explore how partnering with a full-service plastics manufacturer like Port Erie can simplify distribution and logistics for your business.

What Plastics Distribution and Logistics Your Manufacturer Can Take Over for You

Warehousing

Once production is complete, your manufacturer can warehouse your products until you’re ready to ship. When you trust your manufacturer for plastics distribution and logistics services like storage, you don’t need to manage additional shipping steps to a third-party location. This saves you both time and money by keeping all services under one roof.

At Port Erie, we have:

• Two 100,000-square-foot warehouses and one 75,000-square-foot storage facility, providing ample space for both short-term and long-term plastics distribution and logistics needs.
• Contract fulfillment, long-term storage, and seasonal storage options, so you always have storage tailored to your business demands.

Distribution

When you need it, your manufacturer can also manage the distribution part of your plastics distribution and logistics needs. This takes the burden of organizing deliveries off of you and removes the need for an outside distributor, saving you time and money.

At Port Erie, we handle fulfillment for all major retailers, offering flexibility to get your products to big-box stores quickly. We also offer Just-in-Time (JIT) delivery, shipping parts directly to your manufacturing locations on schedule to minimize or even eliminate delays in your production line.

Reporting

Finally, it’s essential to know that your products are reaching their destinations on time. Manufacturers who provide detailed reporting can give you the peace of mind that your plastics distribution and logistics are running smoothly and your products are on track.

At Port Erie, we offer client reports and Electronic Data Interchange (EDI) capabilities to help you track each shipment. By using industry-leading practices, we’re also able to ensure that every part is shipped on time and to the correct location.

Benefits of Trusting Your Manufacturer with Plastic Distribution and Logistics

Outsourcing plastics distribution and logistics to your manufacturer allows you to focus on other aspects of your business. Without the added responsibility of overseeing storage and delivery, you’ll have more time to attend to the operations and planning that drive growth.

By choosing a manufacturer who handles warehousing, distribution, and reporting, you also eliminate the need for separate warehousing and distribution partners. This saves you the time spent on sourcing and coordinating and can reduce costs, since everything remains streamlined under one roof.

Port Erie Offers Various Plastic Distribution and Logistics Services

At Port Erie, we bring more than seven decades of experience to every project, refining our injection and structural foam molding capabilities to deliver high-quality plastic components quickly and efficiently. By integrating our warehousing and distribution services into our turnkey manufacturing solutions, we ensure that your products are produced, stored, and delivered according to your unique specifications — all within a single, streamlined process.

Our plastics distribution and logistics services are designed to support your production goals with efficiency and reliability. Whether it’s JIT delivery, managing stock in one of our large, secure warehouses, or offering detailed reporting to keep you informed, our logistics services are equipped to enhance your operations.

If you’re ready to optimize your distribution and logistics process, reach out to our team today to discuss how Port Erie can help meet your unique needs.

How Automated Injection Molding Has Benefitted the Industry

How Automated Injection Molding Has Benefitted the Industry

Automation is everywhere in our world today, including in manufacturing and plastic injection molding. Automating various production processes offers many benefits to the manufacturer, customer, and end-user. By implementing automated injection molding processes into our business, we have been able to streamline processes, saving our customers money and getting their products to market faster. Let’s explore the benefits of automated injection molding.

What is Automated Injection Molding?

Automated injection molding combines robotic manufacturing equipment and automated tools to create a faster, easier, and more reliable manufacturing process for both large and small parts. At Port Erie, we have implemented automated machines and processes into our injection molding and structural foam molding operations.

Some of the applications of these automated machines include:

• Loading and unloading polymers, materials, and parts
• Quality control by orienting parts and utilizing sensors to determine if there are dimensional errors
• Assembly, sorting, and stacking, including welding to build assemblies and arranging parts for kitting or packaging
• Secondary processes such as decorating and labeling

Benefits of Automated Injection Molding

Faster Production

Automated machinery can work faster and longer than traditional human workers during various manufacturing processes. This allows the machines to create more products in a shorter timeline, and work longer to meet demand faster than traditional manufacturing methods.

Lower Costs

Since fewer human employees are needed for automated injection molding, there are lower labor costs, and manufacturers can pass these savings on to their customers. Additionally, automated injection molding yields more accurate products with fewer mistakes, warpages, or damage, saving you money on having to replace or reproduce products.

Improved Sustainability

Automated machines can produce parts and products with fewer errors, improving fabrication efficiency and reducing the amount of waste generated by deformed and rejected parts. Overall, this greatly improves the sustainability of your production processes, something that is becoming more and more important to end-users due to increased pollution and the growing concern for climate change.

If You Want to Experience the Benefits of Automated Injection Molding, Turn to Port Erie

At Port Erie, we have been honing our injection and structural foam molding capabilities since 1953. With over seven decades of experience, we have mastered traditional injection and structural foam molding processes and have integrated automated systems to keep our production running smoothly, efficiently, and rapidly.

In addition to our injection molding and structural foam molding capabilities, we have all of the capabilities needed to make sure your project runs perfectly from start to finish. Our plastic engineers will help you review your designs to make sure they work for your chosen production process, and if not, they will suggest changes. In addition to this, your assigned plastic engineer will help keep your projects on track during production as well, troubleshooting any issues that pop up along the way and keep you up-to-date on everything that is going on with your project.

We also have in-house tooling facilities, giving us the ability to machine your tooling and molds so we can control the quality of your product from the start. And, once your product is done in production, we can help you with kitting, assembly, decorating, and secondary operations so your product is as aesthetically pleasing as it is functional.

With our multiple warehouses, we can store your products for you until distribution, and we can help with just-in-time delivery.

If you are ready to get started, reach out to our team today.

Structural Foam Injection Molding Large Parts: An Efficient Solution

Structural Foam Injection Molding Large Parts: An Efficient Solution

Large parts can be time-consuming and costly to manufacture, and finding a manufacturing process that meets all of your needs without breaking the bank can be tricky. Fortunately, structural foam injection molding can be used to create large parts in a tight timeline and within budget. Continue reading to learn about the benefits of structural foam injection molding large parts.

What is Structural Foam Injection Molding?

The structural foam molding process starts by mixing a melted polymer with nitrogen gas and/or a chemical blowing agent. This mixture is then injected into the structural foam mold under low-pressure. As the polymer touches the walls of the mold it cools, forming a product with a solid exterior and a honeycombed interior. This process results in large, complex products that have a durable exterior layer, and a less dense inner layer that makes them lightweight compared to their straight injection molded counterparts.

There are two common polymers used in the structural foam molding process to create large parts: polyethylene and polypropylene. Both polymers have beneficial properties, but are often used for different applications. Polyethylene is resistant to chemicals and water, recyclable, has a high strength-to-weight ratio, exhibits low moisture absorption, and has a high impact strength. Polypropylene is rigid, lightweight, tough, and flexible, exhibiting good fatigue, chemical, and moisture resistance.

Benefits of Using Structural Foam Injection Molding for Large Parts

Design Flexibility

Since structural foam molding is a low-pressure process, it is easy to mold. Due to the low-pressure used in the process, the risk of damage to the product is greatly reduced, allowing you to design complex products that will maintain the desired shape in the finished product.

Reduced Risk of Damage and Warpage

As stated above, this process uses low pressure. This puts less stress on the product during the production process. With the reduced stress on the product, your risk of having a damaged or warped product coming out of production is greatly reduced. This will save you time and money in the long run, as you won’t have to worry about replacing or reproducing damaged or warped parts.

Multiple Molds Can Run at Once

During structural foam molding, multiple molds can run at once because the low-pressure process doesn’t put too much stress on the machines or the molds unlike in traditional injection molding. And, since you can run more than one mold at a time, you will be able to create more products in a shorter amount of time, saving you money on manufacturing and allowing for your products to get to market faster.

Advantageous Physical Properties

Structural foam molded products exhibit many desirable properties. Both polyethylene and polypropylene have advantageous properties, and they pass these on to your products. Some of the most beneficial properties this process offers include high strength-to-weight ratio, good thermal stability, and chemical and moisture resistance.

Use Structural Foam Injection Molding for Your Large Parts By Partnering with Port Erie

Port Erie Plastics has been in the injection and structural foam molding industry since 1953. In that time, we have honed our skills and abilities, allowing us to take on the most complex projects for a wide range of industries.

Our team is here to help make sure your project is a success from the start. Each of our clients is matched with a plastic engineer who works with you to understand the application and requirements of your projects so they can make sure the design and material you have chosen are right for you. We also have the ability to create all of our molds and tooling in-house, allowing us to ensure quality from the start.

We offer traditional and automated injection molding, as well as structural foam molding to make sure we can serve all of your needs. Once your product is manufactured, we offer assembly and finishing services as well as warehousing and distribution to make sure your project makes it to the end-user in perfect condition.

Are you ready to get started? Contact us today.

What Are the Different Types of Plastic Injection Molding?

What Are the Different Types of Plastic Injection Molding?

There are a few different types of plastic injection molding to choose from when deciding on a manufacturing process for your plastic project. Two of the most common types are structural foam molding and injection molding. In this blog, we will review each of these processes to help you decide which is best for your project.

Common Types of Injection Molding

Structural Foam Molding

The structural foam molding process creates large tonnage products that are lighter in weight than straight injection molded products. To do this, the process starts with nitrogen gas and/or a chemical blowing agent being mixed with the chosen melted polymer. The mixture of polymer and nitrogen gas/chemical blowing agent is then injected into the mold under low pressure. As the mixture touches the walls of the mold, it forms a solid outer layer and a honeycomb interior, yielding a durable, lightweight product.

This type of injection molding is commonly used to create large tonnage parts and products with thick walls. These walls also allow products to be extremely durable. The low-pressure injection molding process also prevents damage and warpage, allowing for your product to be created with little risk of damage.

Injection Molding

During the injection molding process, a polymer is melted inside the injection molding machine. Then, the machine is closed and the mold halves come together and are held together by high clamp pressure. A screw within the barrel of the machine then pushes molten polymer into the mold under very high pressure. Once all material is in the mold, the screws pull back and the polymer starts to cool. Once completely cooled, the product is released from the mold.

Injection molding is commonly used to create complex parts and products. The high pressure of the process allows for the polymer to get into all sections of the mold, no matter how intricate the design is.

Benefits of Each Type of Plastic Injection Molding

Benefits of Structural Foam Molding

Structural foam molding provides many benefits if used in the proper applications. Not only is it a cost-effective manufacturing process for large parts and products because they can be completed in one shot, but they also offer weight reduction compared to solid plastic parts of the same size. The process is also highly moldable, making it efficient.

Benefits of Injection Molding

The injection molding process is faster than other plastic production processes due to the high pressure at which it takes place. This process produces strong and durable plastic products that can be used in many industries. Plus, this process creates products that have smooth features, so they will need very little post-machining processing, ultimately saving you time and money.

For All Types of Plastic Injection Molding, Turn to Port Erie

Since 1953, Port Erie Plastics has been creating high-quality durable products through injection molding, automated injection molding, and structural foam molding. Throughout our time, we have honed our skills in each of these areas and we brought in multiple skilled plastic engineers to make sure we are producing the best products possible.

When you partner with us, we will assign one of our plastic engineers to your project. They will help make sure your product’s design is conducive to the production process you have chosen, and if not, they will make suggestions to improve the design. From here, you will choose your polymer. Our team has experience with a range of plastics, so no matter which you pick, our team is ready to handle it.

Not only will we help you during the design process, but we also have the capabilities needed to create and design your injection molding and structural foam molding tooling and molds for your project. This allows you to keep your entire production process with the same manufacturer, saving you time and money on your processes.

If you are looking for the perfect partner for your injection molding and structural foam molding projects, turn to Port Erie Plastics. Reach out to our team today to learn more.

What Structural Foam Molding Materials Do You Need for Your Project?

What Structural Foam Molding Materials Do You need for Your Project?

This process is used in many industries due to the products having a lighter weight compared to straight injection molded products while still maintaining durability and functionality. Structural foam molded products are a good replacement for aluminum, steel, and sheet metal, also lowering costs. So, what structural foam molding materials do you need for this process? Let’s explore.

What is Structural Foam Molding?

Structural foam molding is a low-pressure injection molding process where a melted polymer is mixed with nitrogen gas or a chemical blowing agent. This mixture is then injected into a mold. Once in the mold, the gas or blowing agent is released and expands, undergoing a chemical reaction that causes foam to form. When the foaming plastic touches the walls of the mold, it solidifies, producing a solid outer layer and a honeycomb interior.

Structural Foam Molding Materials For Each Step of the Process

Design

During the design process, you will need to choose the polymer you are going to use in production. This polymer will give your product all of the qualities you desire, so it is crucial to choose properly.

In structural foam molding, there are two common polymers used: polypropylene and polyethylene. Each of these plastics has its advantages and drawbacks:

• Polyethylene: This plastic is known for its resistance to chemicals and water, its recyclability, high strength-to-weight ratio, low moisture absorption, high impact strength, and durability. However, it does exhibit poor weather resistance and is sensitive to stress cracking. Commonly, polyethylene is used to create chemical containers, pipe systems, gardening equipment, and more.
• Polypropylene: This rigid, lightweight, closed-cell polymer is commonly used in consumer goods, automotive, medical, and many more applications. It is known for its toughness, flexibility, fatigue resistance, chemical resistance, temperature resistance, and moisture resistance.

If you aren’t quite sure which polymer will best suit your application, your manufacturer will be able to help steer you in the right direction.

Tooling and Mold Production

The tooling and molds you will be using during production need to be created from durable materials so they can be used repeatedly, saving you money on these tooling costs in the future. It is standard that these molds and tooling are made from steel due to its many advantageous properties. It is known to be strong and durable with the ability to withstand heavy loads and resist deformation with continual use. This allows these products to be used repeatedly without breaking down, reducing costs on maintenance and replacements.

Structural Foam Molding Process

Once you have decided on your polymer and have your tooling created, production can begin. During this process, your structural foam molding project will need either nitrogen gas or a chemical blowing agent to yield the part you desire. These chemicals are crucial to the formation of the honeycomb interior. The nitrogen gas or chemical blowing agent will undergo a chemical reaction during the injection process to form the inner honeycomb layer.

Secondary Operations

After production, you will have the option to tack on secondary operations to make sure your product is exactly as you envision. These services include assembly, decorating, drilling holes, and kitting. At Port Erie, we also offer assembly with screws, nuts, aluminum extrusions, fasteners, velcro strips, spindles, latches, springs, and rods.

Port Erie Can Provide You With All the Structural Foam Molding Materials You Need

At Port Erie Plastics, our team has been completing structural foam molding projects since 1953. During this time, we have become extremely familiar with a wide range of structural foam molding materials, particularly polyethylene and polypropylene. No matter which material you choose for your project, our team is ready to take it on.

Contact us today to get started.