Plastic parts prepared using the Structural Foam process have a cellular or a structural core, surrounded with thick outer layer that combine to give the products greater strength to the weight ratio and as much as twice the rigidity of the solid products that are of the same material and weight.
The structural foam molding process utilizes a molten resin that has been injected with a foaming agent auch as nitrogen gas. Structural foam yields parts that are larger and sturdier than injection molding. Parts produced through structural foam molding process are structurally sound, nearly stress-free and have minimal warpage.
KEY BENEFITS OF THE STRUCTURAL FOAM INJECTION MOLDING PROCESS as below:
- Part weight reduced
- Increased strength and stiffness due to sandwich structure
- Capable of molding large, complex parts without sink marks
- Capable of molding parts .500 inches thick or greater
Shanghai iMolding Co. Ltd. delivers high-quality Structural Foam products to a wide range of industries across the globe. With us, you can avail a huge range of benefits by producing products using Structural Foam Injection Molding process. Some of the benefits include:
Lower Material Costs:
In the structural foam process, the part weight can be reduced up to 30%, thus, lowering the material costs without compromising with the Structural Integrity.
Increased Efficiency at Low Cost:
The capability of a large shot size is up to 150 lbs per shot. To combine various smaller parts, larger products can easily be designed, thus reducing cost and increasing efficiency.
Low pressure Structural Foam equipments have multi-nozzle capability. That means multiple molds can be processed at the same time and on the same press.
Low Pressure Molding
We have also incorporated the use of low pressure structural foam injection molding process which is quite similar to other conventional methods of injection molding except that the foaming agent which is nitrogen gas is mixed with the melted polymer and injected into a mold at low pressures. Also, the mold is usually filled with resin in high pressure molding which doesn’t happen in low pressure molding thereby the polymer mixture is allowed to expand and cover the mold after the process which aids in the creation of rigid plastic part having a reduced density. We are assisting the clients in availing the advantages of low pressure structural foam injection molding as the component weight is hugely reduced from 10% to 30% giving them to have lower costs for the material without resulting any affect on the structural integrity. Besides this, the use of less energy in low pressure molding per pound of plastic fosters in the utilization of less material in finished products and greatly produces large plastic components cost-effectively.
With Shanghai iMolding, you can get a high quality, repeatable, and quick way to make large-size plastic components/products efficiently and cost effectively using Structural Foam Injection Molding.