Frequently Asked Questions

How to increase the strength of a part through Structural Foam Injection Moulding?

In order to increase the strength of a part, volume is often added to specific sections to improve performance.

This adds extra complications into processes that form parts using molten material such as injection moulding or casting. Changes in thickness make for flow and cooling problems; these are seen as cosmetic and structural defects like voids, warpage and sink marks in the finished component.

There is however one method of injection moulding that can overcome these issues – we take a look here.

Structural Foam Injection Moulding

By introducing a gas into the liquid polymer during moulding, a quality part including both thin and thick sections can be produced. This process is know as Structural Foam injection moulding; the end result is a rigid part that looks like a standard injection moulding but has a strong foam core encapsulated in a solid outer skin.

Parts produced in this way have several advantages over those manufactured by more conventional techniques. While exhibiting all the popular qualities of plastic parts such as toughness, aesthetic variation and durability they are also strong and light; often acting as replacements for metal parts therefore supporting assembly, cost and weight benefits.

Both small and large parts in excess of 50Kg can be moulded having a strength to weight ratio of up to 7 times that of steel and an increase in impact stiffness of 20%. Weight reduction can be as much as 30% over alternative methods with section thicknesses in excess of 12mm.

Post Processing options

As with most plastic parts they can be moulded with texture, colour, in-mould decoration and threaded inserts. Parts can be post processed by painting or printing and at the end of life, completely recycled.

If you think Structural Foam injection moulding would suit your project and you would like to know more please contact us. Alternatively for information on other processes please visit our Processes Pages.

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