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Injection molding is surely the best choice for high-volume production of plastic parts. The process is quite simple, as we need to inject the melted polymer into the mold, where it cools down and forms the desired shape and design. No denying that there are multiple benefits of this manufacturing method, but when it comes to producing the same plastic parts with lesser weight, then Structural Foam Molding is possibly the best option.
Described in simple terms, Structural Foam Molding Companies aim to produce plastic parts with the lowest possible weight with minimum compromise on strength and build-quality. The secret lies in the process, which is quite similar to traditional injection molding methods, but with a couple of changes.
In structural foam molding, an inert gas is also added to the melted polymer before injecting it into the mold, which expands and gives a foam-like core structure to final products. Moreover, low-pressure is used for injecting the melted polymer, thereby allowing the chemical blowing agent enough time to get the job done. As a result, final products have 10-30% less weight compared to solid plastic parts built through traditional molding methods.
Now that we know the major differences between structural foam molding and normal molding, let’s take a look at some great advantages offered by this method.
Excellent Strength-to-weight Ratio
Though plastic parts built through this method are light-weighted, still they are strong and durable. This is because of the thick outer walls, which provides excellent strength and durability in end products. The high strength-to-weight ratio is unarguably the most significant characteristic of structural foam molded parts.
Electrical/Thermal Insulation and Sound Deadening
Plastic parts with a foam-like core structure offer excellent electrical and thermal insulation properties. Along with that, sound deadening is also decent in such products, all thanks to tiny air pockets.
Low-cost Raw Material & Minimum Wastage
You may use recycled materials in structural foam molding, which ultimately lowers the overall production cost. Moreover, plastic parts built through this method are also recyclable, thereby minimizing the wastage.
Appealing Surface Finishing With Fewer Secondary Operations
This method simply allows you to build the desired plastic with complex designs, all thanks to low-pressure used for injection process. This is because plastic parts built through this method have an excellent surface finish, thereby no or very few secondary operations are required.
Low Tooling Costs
Since it is a low-pressure molding process, we may use aluminum molds, which are cheaper than steel molds. Thus, it eventually lowers the overall production cost and maximizes your profit. Aluminum molds are surely not as strong as steel molds, though they may last as long as steel molds when low-pressure is used for molding.
Faster Production
Since aluminum offers excellent heat-transfer rate, production can be done at much faster speed. Thus, you’ll be able to fulfil the market’s need at the right time, which improves the company’s image.
So, structural foam molding has several great benefits to offer, but make sure you are using appropriate tools and machinery for this.
