With so many molding processes available, it can be like a puzzle trying to figure out which is best for your product. Luckily, DeKALB is here to clear up the clutter. While injection molding is probably the most common molding process out there, considering structural foam as an alternative can:

  • Create stronger and larger parts
  • Build thicker wall sections
  • Save on the cost of tooling
  • Reduce material costs

Stronger, Larger Parts

Structural foam is lauded for its ability to mold large plastic parts. As it’s a low-pressure molding process using a chemical blowing agent, parts are created with additional “structure” that provides increased strength. Meanwhile, injection molding is limited to mostly small critical tolerance parts.

Thicker Wall Sections

While both structural foam and injection molding offer variable walls, it’s structural foam that gives you the most flexibility – and the thickest wall sections. Structural foam allows a range of thickness from .1875” to .5”, while injection molding is generally limited: .06” to .1875”.

Tooling Cost Savings

It’s all about the bottom line. If you’re looking to get more bang for your buck, structural foam is the way to go. Injection molding has higher upfront tooling costs while structural foam’s low pressure process allows for lower cost aluminum tooling. For larger plastic parts, it’s a no brainer.

Reduced Material Costs

The structural foam process promotes a weight savings of up to 20% versus injection molding due to the foaming methodology. This can equate to both material and transportation cost reductions.

Do you have an application you would like to explore as a structural foam process? Contact us and we will send you a sample kit including examples from above.