DeKalb
Molded Plastics specializes in molding of structural plastic parts utilizing
structural foam, gas-assist, and standard high-pressure injection molding
processes. Structural plastics are an excellent alternative for
wood and or steel replacement, as well as applications where an increase
in rigidity is required. Structural plastics molding also
provides the opportunity to combine multiple parts of an assembly into
one single molded product.
Structural
Foam
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.
The structural
foam process is an extension of the standard injection molding process.
In the structural foam process, a foaming agent is mixed with the polymer
melt and injected into the mold in a volume less than is required to mold
a solid part. The melt in contact with the mold forms an almost solid
skin while the gas expands to form the inner cellular structure.
 |
Low mold cavity
pressure |
|
Reduced part weight |
|
High stiffness to
weight ratio |
|
Capable of molding
large, complex parts |
|
Low cavity pressure
allows lower cost tooling |
|
Low part stress
and warpage |
|
Multiple molds can
be run at the same time |
|
Capable of molding
parts up to .500 inches thick |
|
Functions as excellent
substrate for high quality painted finish applications |
Gas-Assist
The gas-assist
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. The
gas maintains internal pressure throughout the cooling cycle. As
the part cools, the internal gas pressure maintains the mold surface contact
with the part. This allows molding of thick wall sections without
sink marks and without the characteristic swirl appearance of structural
foam.
Key
Benefits
|
Thick, varied, wall
sections can be molded without sinking or warping |
|
Hollow gas channels
function as box sections, which further increases the stiffness to weight
ratio |
|
Gas hollowed channels
allow reduced cooling, and thereby overall cycle time |
|
Allows reduced cavity
pressure, which allows utilization of lower tonnage, more efficient, molding
machines |
Molding Equipment
|
Camp Tons
|
Platen Clearance
|
Tie Bar
Clearance
|
Capacity
|
Multi-Nozzle - 7
|
300
|
86 X 86
|
45 X 67
|
43 lbs.
|
|
300
|
86 X 86
|
43 X 65
|
50 lbs.
|
|
300
|
86 X 86
|
45 X 67
|
100 lbs.
|
|
300
|
112 X 76
|
50 X 86
|
50 lbs.
|
|
400
|
86 X 89
|
58 X 67
|
100 lbs.
|
|
500
|
98 X 89
|
58 X 67
|
150 lbs.
|
|
750
|
130 X 86
|
104 X 45
|
100 lbs.
|
Single-Nozzle - 1
|
1000
|
65 X 65
|
52 X 44
|
16 lbs.
|
Auxiliary Molding
Equipment
10 - Ton Overhead Crane
4 - Outdoor Silos - 100,000 lbs. each
1- Indoor Silo - 65,000 lbs.
Conair Blending Systems
Conair Central Vacuum System
If you
have any questions concerning our capabilities or you have any business
opportunities you would like to discuss, please contact our Director of Sales
Chester Kos at ckos@dekalbplastics.com
550
West Main St.
Butler,
IN 46721
Phone
260-868-2105
FAX
260-868-2537
