Process: Structural foam / web

Ideal for injection molding lightweight, low cost, durable structural plastic parts, the Structural foam process has a cellular foamed core surrounded by integral skins, forming a total integral structure. In this process a foaming agent (N₂ or CBA) is mixed with the polymer melt and short shot through a modular multiple nozzle system into the mold or molds in a volume less than is required to fill a solid part. Both the injection pressure and expanding gas/polymer cellular mixture act to fill the mold. The mold cavity pressures are 10 - 20 times lower than conventional injection molding which also permits the use of lower cost aluminum molds.
The Structural Foam UMSF process is recommended for injection molding large structural plastic products such as indoor/outdoor furniture, large appliance components, construction products, material handling bins and pallets, building products, toys and recreational items.
Structural Web UMSW is an optional molding process that has similar advantages to Structural Foam. Parts are solid without foam but are packed out by internal gas pressure that produces hollow channels and hollow thick sections. The UMSW process has the added benefit of an improved smooth solid color surface and faster cycles for very thick section parts.