Structural Foam Molding (Low Pressure Injection)

Structural Foam Parts

Structural foam molded parts have low density cellular cores surrounded by near-solid integral skins.
The transition from skin to core is gradual. The solid skin gives the molded part its form and toughness,
while the core contributes to the high strength-to-weight characteristics normally associated with this type
structure.

Cross Section of Structural Foam Part

Structural foam molded parts are usually large, heavy and have thick walls. Wall thickness is typically in the
range in excess of 4 mm (.150 in) up to 12.7 mm (.500 in). Parts weighting over 68 kg (150 lbs) are being
structurally foam molded.
Advantages of Structural Foam Molded Parts
•High strength-to-weight ratio.

•3 to 4 times more rigid than a solid part of the same weight due primarily to the thicker wall cross
sections.

•Greater part stiffness and resulting load carrying capacity than conventional IM part.

•Lower part weight due to reduced density.

•Lower raw material cost due to reduced density or use of less expensive resins. Commodity
resins may be utilized in load bearing applications.

•Lower manufacturing costs due to less costly production methods.

•Ability to combine many parts and functions into a simplified single part design.

•Minimize sink marks even on parts with unequal section thicknesses.

•Low stress concentrations due to cellular structure.

•Bowing and warping are greatly reduced.

•Characteristics include chemical resistance, sound-deadening, electrical and thermal insulating

qualities.

•Parts can be painted or nailed.

Low Pressure Structural Foam Molding Process

Structural foam molding is similar to conventional

injection molding with the exception that it is a two-
stage extrusion/injection molding process, normally
uses inert gas as a foaming agent, and injects a short
shot into the mold(s) The machine has some unique
features including a multiple nozzle system, an
external hot manifold, and building block manifold
extensions. The nozzles can be mounted at any
location along a six-inch grid drilled into the stationary
platen. They can be located in ideal locations to inject
at multiple points into a single mold or multiple molds.
The flow lengths can be minimized by strategic
placement of the nozzles. The main manifold mounted
externally on the fixed platen with building block
manifold extensions act as hot runner systems and
can be repositioned accordingly.
Configurable Multi-Nozzle Manifold