Processes

DeKALB Molded Plastics prides itself on the ability to engineer plastic product designs, and manufacture custom molding solutions. Whether you need minor design assistance or full concept to reality project management, no job is too big. We proudly offer the following processes…

Structural Foam Process
The structural foam process allows production of rigid plastic products which have a cellular foamed core surrounded by an outer skin forming a total integral structure. Products molded with the structural foam process have a high strength to weight ratio and are 3 to 4 times more rigid than solid parts of the same weight.

Gas Assist Molding
The gas assist molding process utilizes nitrogen to hollow out large, thick, wall sections. The gas does not mix with the resin, but instead forms continuous channels through the hotter, less viscous, sections of the melt stream. This allows molding of thick wall sections without sink marks and without the characteristic swirl appearance of structural foam.

High-Pressure Injection Molding Process
High Pressure Injection Molding produces cosmetically superior parts and allows tremendous design flexibility.