Structural Foam Molding - CORE Molding Technologies

Raw Material

Structural Foam Molding is the combination of inert nitrogen gas and thermoplastic resin. This blend is crucial for creating distinctive solid outer skin with a cellular interior for molded parts. The cellular interior not only reduces the weight of the product but also enhances its strength and durability.

If you are looking for more details, kindly visit WIT MOLD.

Aluminum Tooling

The tooling process for Structural Foam Molding involves the use of a cavity injection mold. Typically, manufacturers construct these molds from machined aluminum billet or castings for precise and long-lasting results. This process doesn’t need steel molds, saving money on capital costs compared to other molding methods.

Molded Part Finish

The gas-assist molding process utilizes a chemical blowing agent to move the nitrogen through the part. Structural Foam molding creates a robust outer layer with an industrial appearance and a cellular center. This unique finish ensures that the product is lightweight yet strong, making it ideal for a range of applications.

Cut weight & material use

Structural Foam Molding can decrease part density by 10-30%. This reduction doesn’t compromise the strength of the product. In fact, the resulting parts have an impressive strength-to-weight ratio, making them both efficient and cost-effective.

Create Large Parts

Structural Foam Molding is a game-changer for producing large parts because it can accommodate large shot sizes. At Core Molding Technologies, our machines can accommodate up to 100 pounds of material in a single shot.

Save time when putting parts together

Combining smaller components into a single large part can reduce complexity. After serving the transportation and powersports industries for many years, our teams understand how to save you time. Converting numerous small parts and assemblies into a single molded part makes your downstream activity more efficient. Imagine creating vast structures from plastic that you previously thought were impossible.

Reduce your logistics costs

Transitioning to Structural Foam Molding can lead to significant savings in logistics. We have replaced heavy materials like concrete and steel with lightweight foam to transport and install things in a different way.

Large Platens all for Multiple Molds & Family Tools

Efficiency is at the core of Structural Foam Molding. The process allows multiple molds to run simultaneously, leading to significant savings in cost and lead times. Parts molded at the same time with a single “family” tool are more consistent. Parts made together using one “family” tool will fit and have the same color.

Process Flexibility with Recycled Materials

Sustainability is a growing concern in today’s world. Structural Foam molding enables parts to consist of up to 100% post-industrial or post-consumer materials. This not only diverts waste from landfills but also ensures that all Structural Foam products are 100% recyclable. Furthermore, the low-pressure molding technique consumes less energy and material per pound compared to other molding methods.

Dimensional Stability and Consistency

Are you interested in learning more about precision injection molding? Contact us today to secure an expert consultation!

One of the challenges with traditional molding processes is the internal stress they introduce into the part. Structural Foam Molding, with its lower tonnage pressure, minimizes this stress. The resulting parts feature enhanced uniformity, dimensional stability, and reliability under various environmental conditions.

Flexible Colors and Textures

Structural Foam Molding offers a plethora of design options. Core Molding will meet your design requirements based on colorants or textures. This flexibility eliminates the need for additional post-processing, which can be both costly and environmentally detrimental.

If you’re considering injection molding for your next project, it’s important to know that you have options when it comes to techniques. Structural foam injection molding and traditional injection molding both produce high-quality plastic parts. However, key differences in the manufacturing processes result in unique material properties, costs, and applications. Understanding these differences helps determine the right process for the project.

In this blog article, we’ll compare and contrast structural foam molding and traditional injection molding. You’ll learn what each process entails and the advantages of each so that you can choose the right approach for your unique needs.

WHAT IS STRUCTURAL FOAM INJECTION MOLDING?

Structural foam injection molding is a plastic manufacturing process that utilizes a foaming agent (also called a chemical blowing agent) and low pressure. It works by heating thermoplastic material until it becomes molten and then introducing the foaming agent, which causes the plastic to expand and form the foam structure. The material is injected into a mold under low pressure, and the blowing agent expands within the mold cavity. The surface cells collapse when the material contacts the mold walls, resulting in a core of interconnected cells (like a honeycomb) surrounded by outer layers that make up a smooth, dense, and solid skin. The material solidifies as it cools and creates a lightweight but strong product.

ADVANTAGES OF STRUCTURAL FOAM MOLDING

The structural foam molding process offers the following advantages:

• Weight Reduction: The foam core allows for reduced part weight, which is critical in industries like automotive and construction, where material savings can translate to cost savings and energy efficiency.
• Material Strength: Despite its lightweight nature, the cellular structure of the foam provides high structural integrity, making it ideal for parts with thicker walls or heavy cross sections. Structural foam parts are less susceptible to deformation or mechanical stress, compared to their traditional counterparts.
• Thermal Insulation Properties: The foam core enhances thermal insulation, making this process beneficial for products like building insulation panels or thermal insulation components.

WHAT IS TRADITIONAL INJECTION MOLDING?

Traditional injection molding works similarly to the structural foam process. However, no foaming agent is utilized and the molten plastic is injected into the mold under high pressure. Traditional injection molding is widely used for smaller, more complex parts in industries like consumer electronics, medical devices, and automotive trim.

ADVANTAGES OF INJECTION MOLDING

The advantages of the injection molding process include:

• Precision: Traditional injection molding is ideal for parts requiring fine details and a smooth surface finish. It’s often used for consumer-facing products where aesthetic quality is paramount.
• Strength & Durability: Solid parts produced through this method offer consistent strength, making it preferable for applications where structural integrity is critical, such as mechanical components.
• Diverse Material Compatibility: Traditional injection molding is compatible with a variety of materials like polyethylene, polypropylene, nylon, polycarbonate, and more.

HOW STRUCTURAL FOAM AND TRADITIONAL INJECTION MOLDING DIFFER

Structural foam and traditional injection molding each have unique benefits, but it’s important to understand their differences before choosing the best method for specific projects.

PRESSURE AND PROCESS

• Structural Foam Molding: This process operates at low pressure, reducing wear and tear on molds and lowering production costs for large parts.
• Traditional Injection Molding: This process uses high pressure, which allows for greater precision and is essential for producing parts with tight tolerances.

PRODUCT DENSITY AND WEIGHT

• Structural Foam Molding: Structural foam products are lighter due to the foam core, making them ideal for large-scale components like foam boards, warehouse bins, or even trench walls in construction.
• Traditional Injection Molding: Injection molded products are solid and denser, which is crucial for mechanical components where mass density and material uniformity are important.

SURFACE FINISH

• Structural Foam Molding: Due to the cellular foam structure, parts often have a slightly coarser finish compared to traditional injection-molded parts. This is less important for internal or structural components where surface finish isn’t a priority.
• Traditional Injection Molding: Provides a smooth, consistent surface finish, making it ideal for consumer products or anything requiring a high-quality aesthetic.

MATERIAL COST AND EFFICIENCY

• Structural Foam Molding: This manufacturing method typically uses less material due to the foam core, leading to cost savings for large parts. The low-pressure process also allows the use of aluminum molds, which are less expensive than steel molds commonly required for traditional injection molding.
• Traditional Injection Molding: When using this method, more material is required for solid parts, and the molds tend to be more expensive. However, it’s more cost-effective for high-volume production of small, precise components.

APPLICATIONS: WHICH PROCESS TO CHOOSE?

So, now that you know more about structural foam injection molding and traditional injection molding, their advantages, and how they differ from one another, you should be better equipped to determine which process makes the most sense for your needs.

However, if you want a little more information before you choose, below are some recommendations for best-use scenarios.

BEST USES FOR STRUCTURAL FOAM INJECTION MOLDING

Structural foam molding is a good choice if you need:

• Large, Durable Parts or Products: Examples include pallets, trench shields, or building insulation boards.
• Load-bearing Components: Items requiring rigidity and strength without excessive weight, such as automotive parts or structural panels.
• Cost-sensitive, High-volume Production: For example, warehouse shelving or construction molds.

BEST USES FOR TRADITIONAL INJECTION MOLDING

Injection molding is a good choice if you need:

• Precision Parts: Products where intricate details and smooth surfaces are necessary, such as medical devices, consumer electronics, or plastic housings.
• Smaller Components: Items requiring tight tolerances and high precision like machine components.

CHOOSING THE RIGHT INJECTION MOLDING PROCESS

The choice between structural foam injection molding and traditional injection molding depends on your specific needs. For large, durable, and lightweight components with thicker walls and high structural integrity, structural foam molding is a great solution. On the other hand, if precision, smooth surfaces, and fine details are key to your product, then traditional injection molding is your best bet.

Want additional guidance from experts and optimal solutions from a high-quality plastic manufacturer? Contact Cooper Plastics today to learn more or request a quote. We can produce not only structural foam molded parts and injection-molded components but also web core products, which feature solid construction with hollow channels and hollow thick sections. This kind of versatility is fairly rare in the plastic manufacturing industry and enables us to produce a wide range of products that are durable and cost-effective.