North American Manufacturing-Great Design and Build
The benefits and applications
of structural foam.
Structural Foam Molding is a plastic molding process ideal for production of large complex plastic parts that are rugged, durable and impervious to the elements. They are used in industry, recreational vehicles, commercial truck parts and products, outdoor consumer products and even underground applications.

For detailed illustration of the technology visit our structural foam molding process overview.

The process is similar to injection molding in that you have a precision mold mounted in a molding machine. After resin injection, the mold opens up and the part is ejected from the mold cavity. This is where the similarity to injection molding ends. Structural foam parts are produced at a much lower pressure than injection molding and inert gas is used to fill the mold cavity instead of machine pressure. The result is a cellular core with solid plastic exterior walls.

What are the advantages of structural foam? There are many but here are major ones:

  1. 1. Better for larger parts because of the lower pressure used to fill the mold cavity. Lower molding pressure allows for the use of smaller tonnage molding machine and aluminum molds.
  2. 2. Lower molding pressures mean less stress and more stable design geometry.
  3. 3. Cellular core produces lighter weight parts, higher impact strength and better strength to weight ratio.

How can you get started?

Call us at 216-533-1410 or send a RFQ to start the conversation! We can quickly advise you on your product suitability for structural foam molding manufacturing. We also can assist with design, engineering, mold making and material selection to get your project started right.

Please visit our image gallery to see specific examples.