Benefits of structural foam molding

Benefits of structural foam molding

Summary:The types of foam products are endless. Based on traditional...

The types of foam products are endless. Based on traditional foaming process, microcellular foaming technology, ultra microcellular foaming technology, reaction injection foaming technology, rotational molding foaming technology, structural foaming injection molding technology, low foam extrusion molding technology, blow molding foam molding technology, NIR technology, Such as dynamic pressure release and cooling (DDC) technology.


The use of structural foam as a manufacturing material has many advantages. Among the advantages of C-structured foam molding, structural foam was originally known for its ability to produce unmatched dimensions such as vehicle roofs and body panels. However, it is clear that structural foam is expected to provide many other benefits.


Structural foam components are extremely lightweight, with typical weights ranging from 55 pounds / cubic foot to just 2 pounds / cubic foot. In addition to being lightweight, the structural foam is strong, durable and extremely stiff. In fact, its stiffness is eight times that of solid polymers and similar materials. The modulus of the material increases with density, reaching a staggering 250,000 psi. In addition, since it is a foam, it is a material with excellent heat insulation and sound insulation.


Structural foams are also easy to mold. One part can produce different wall thicknesses. In some cases, structural foams can produce wall thicknesses greater than the previous maximum of ½ inch (13 mm). Due to the low viscosity of the mixture, the ribs and protrusions can also be thickened, reducing the risk of “subtraction” of the ribs and cross-section area. Structural foam products generally have low stress during molding and have high resistance to warpage and deformation.

In addition, structural foam retains the impact, element, and high temperature resistances common to thermoplastic and thermoset polymers. With little or no thermal expansion, it is well suited for products used in various climates and temperatures. The acoustic and acoustic damping properties of structural foams are superior to standard solid polymers.


Structural foam molding is also a cost-effective process. Due to the low pressure and clamping forces required during injection and curing, molds and dies can be made of low cost materials such as aluminum. Cycle time competes with injection and reactive injection molding time, saving both time and money.


The risk of structural foam product damage during molding or disassembly is below average, making it an efficient and easily repeatable method. In addition, structural foam does not generate potentially harmful styrene fumes, which reduces worker health risks during the molding process.


Finally, structural foam is highly sprayable and has a beautiful surface. All structural foam products can be painted in-mold (PMI), further saving time and money. You can also apply multiple colors to a single part mold. The surface is easy to clean and can be sewing, twisted, nailed and stapled without any problems.


Structural foams can be used for products with a wall thickness of more than 5 mm or products with a sudden wall thickness. This product is a high-density one-piece foam material, with higher strength and stiffness per unit weight than non-foamed materials of the same type. Structural foam products not only have four times the flexural rigidity, but also have few reinforcing ribs, can eliminate sink marks due to wall thickness, have low internal stress concentration, and are unlikely to undergo large deformation during use