Exploring Structural Foam Properties

Structural foam molding is a great plastic manufacturing method for large objects and the inherent structural foam properties are beneficial to both the manufacturer and the customer. This allows manufacturers to easily create large plastic parts and products that are durable.

Structural foam molding begins when nitrogen gas or a chemical blowing agent is mixed with a melting polymer. This polymer mixture is then injected into a mold under low pressure. As the plastic touches the walls of the mold, it cools and solidifies, creating a solid outer layer with a honeycomb interior.

Structural Foam Properties You Should Consider

Weight Reduction

There is a considerable weight reduction between large injection molded products and large structural foam molded products. Due to the honeycomb interior, structural foam products are lighter than if the same part was made with straight injection molding. This allows these products to be used in a wide range of industries and in applications where injection-molded parts are simply too heavy.

Strong and Durable

The plastics that are used for the structural foam molding process have a higher rigidity than the plastics that are used in injection molding. This structural foam property results in a strong and durable plastic product.

Highly Moldable

Since the process is low-pressure, structural foam is highly moldable. It experiences less stress during the low-pressure molding process which reduces the risk of warping or deformities. This reduces the amount of products that are damaged during the manufacturing process, keeping it moving smoothly and saving you valuable time and money.

Reduced Resource Use and Waste

The process of structural foam molding uses fewer raw materials and less energy during production. Additionally, post-industrial scrap plastic is often used as a primary feedstock. This allows products to be manufactured in a more sustainable manner which is becoming increasingly important to consumers.

Cost-Effective Manufacturing Solution for Very Large Parts

Structural foam molding is a cost-effective manufacturing process for creating very large, thick parts, and very specific parts. This is because it is a low-pressure process, requiring less clamping force during the injection and curing processes. Because the clamping force is lesser, tooling and molds can be made from less expensive materials, such as aluminum. Producing very large parts and products can be costly, so saving money with structural foam molding can increase your profit margins.

Talk to the Experts at Port Erie to Learn How Structural Foam Properties Could Work for Your Project

At Port Erie, we have over 70 years of experience in plastic manufacturing and structural foam molding. We can produce parts up to 150 pounds, 7.5 feet in length, and with a wall thickness ranging from 0.200 to 0.500 inches with our structural foam molding machines. You can choose from polyethylene or polypropylene for this process depending on the structural foam properties you desire.

Not only are we expert structural foam molders, but we also specialize in injection molding and engineering. Our trained engineers will help you determine which process is best for the production of your products and what polymer may be the best fit for you.

If you are looking for a trusted structural foam molder, turn to Port Erie. Contact our team to get started today!