As a custom structural foam molder specializing in large, multi-nozzle plastic products, DeKALB Molded Plastics has more than 40 years of experience serving our customers as a trusted business partner. We believe in structural foam because, at DeKALB Molded Plastics, we are structural foam!
The Basics of Structural Foam
A simple question that is often asked to us is, “what are the characteristics of structural foam?” Since structural foam is not a material but rather a manufacturing process, it’s not easy to answer this question. What is structural foam? Structural foam plastic molding is an injection molding process that utilizes a foaming agent and/or nitrogen gas that mixes with the base resin in the polymer melt before being injected into the mold.
What Materials are used in the Structural Foam Process?
As the case with most plastic manufacturing processes, polymers are used. There are two main categories of polymers, thermoplastics and thermosets. The main difference between the two is thermosets cannot be recycled, while thermoplastics can. At DeKALB, we primarily work with thermoplastics and can mold almost all of them. Under the thermoplastics umbrella lies three general groups of resins - commodity, engineered and performance. DeKALB Molded Plastics mainly focuses on commodity resins, but we mold many engineered resins as well. True to our commitment to providing unrivaled customer satisfaction, we have the flexibility and experience to work with all three types. In addition to the resins that we work with, DeKALB is also equipped to add additivities including talc, glass-fiber, impact modifiers and, in some cases, crumb rubber.
Structural foam has great recyclability, as parts molded in this process can be made from virgin material or recycled material. From there, the part, whether originally from virgin material or recycled material, can continue to be recycled, and subsequently, remolded again and again.
What Does DeKALB Molded Plastics Do?
Simply put, we mold big, heavy-duty thermoplastic parts. Generally, the guidelines for the parts that we produce weigh between 3 and 150 pounds, dimensionally parts are a 1’ x 1’ square, up to 4’ x 8’, similar to a sheet of plywood, and 30” deep. The thickness of the parts produced ranges from 3/16” to 3/8+” (4.7mm to 10mm).
We have the capabilities to go slightly outside of those boundaries getting close to 6 feet by 6 feet or just under 36 square feet. As always, depending on the application, there are some instances where we can go larger. As for the thickness of the part, we can go thicker or thinner, though when making a part thicker, it is usually more cost-effective to add strength with ribbing rather than thicker sections of plastic. Additionally, when making a part thinner than 3/16”, there are more considerations to make and pay attention to during the process.
DeKALB has a long and proud history of producing custom molded products for multiple market segments. Some examples of the products that we mold include:
- Yellow barrels – (Seen on highways)
- Underground enclosures
Can You Paint Structural Foam Parts?
From the color of your kitchen to the shoes that you wear, being able to customize something to get exactly what you want is important, and the same is true for the parts that we make. Providing custom solutions, in exactly the color you need, is just one of the ways DeKALB effectively serves our customers. Structural foam parts can be painted, and there are two ways to go about creating parts in a certain color. The part can be molded in color with colorants mixed in or color can be added during secondary operations. To meet your exact specifications, we either add colorant into the foam-resin mix or our in-house paint shop can meet the specific color requested.
We Are Structural Foam
Do you have questions about structural foam? Visit our structural foam FAQ’s.
When you work with us, you work with a partner that is committed to your solutions, providing the answers to your structural foam needs. With a wide range of capabilities in plastic processing and an experienced team of engineers, operators and quality technicians, DeKALB Molded Plastics is up to the challenge. Ready to discover what DeKALB can do for you? Contact us today!