Structural Foam Forming: Frequently Asked Questions

What is structural foam forming?

Structural foam molding is a process most commonly used to produce large structural parts. Structural foam molding tends to produce thicker walls than other injection molded parts; as a result, structural foam molded parts have a strong and durable surface. During structural foam molding, an inert gas (usually nitrogen) is mixed with the plastic material before it is injected into the mold. As the material is injected into the mold, the gas expands and the plastic hardens as it comes into contact with the cold mold cavity. This process allows for the manufacture of durable products at lower pressures than are typically required using other injection molding processes.

 

What are the advantages of structural foam molding?

Increased strength and stiffness. The honeycomb structure within the parts gives them a very high strength-to-weight ratio and stiffness-to-weight ratio.

No shrinkage on thick parts. You can break a lot of old rules of thumb about part thickness. This gives you the opportunity to make thick, complex parts without dents.

Low stress and warpage. The low-pressure process eliminates these problems.

Superior impact resistance. This is again due to the honeycomb structure.

Sound insulation and electrical/thermal insulation properties. Due to the tiny air pockets within the part.

Lower cost aluminum tooling. Excellent aluminum results due to the use of lower pressures.

Faster cycle times. This is due to the better heat transfer of the aluminum mold.

Lower material costs. Recycled post-consumer materials can be used in the process and the parts produced can be recycled.

Attractive surface characteristics. Parts have a consistent surface finish to get the texture you want.

Excellent substitute for other materials. Parts can replace a wide range of materials, from concrete to sheet metal to fiberglass to wood.

Long tool life expectancy. Despite the use of aluminum tools, it typically lasts as long as steel due to the lower stresses used.

 

Are there disadvantages to structural foam molding?

No injection molding process is perfect, and structural foam molding does have some drawbacks. The process itself takes longer, which means you will have to invest more time in producing structural foam molded parts. Before choosing structural foam molding, it is important to consider how these additional production times will affect your overall performance and productivity.

 

Have more questions about structural foam molding?

If you have more questions about structural foam molding, be sure to get the answers you're looking for from WIT MOLD. We are injection molding and engineering experts with extensive experience in handling a variety of injection molding processes. To get answers to all your injection molding questions and start using our services, contact WIT MOLD today.