First of all, structural foam is a process, not a specific material. In general, structural foam increases the compressive strength and flexural modulus versus solid plastic. Impact strength and tensile strength can have a slight reduction.

Dimensionally, we can produce parts up to 4’ x 8’ and 30” deep. We have machines that hold 150 lbs of plastic, so we can produce some very large parts.

Thickness ranges from 3/16” to 3/8” (4.7mm to 10mm). We can go thicker, but usually find it to be more cost effective to add strength with ribbing rather than thicker sections of plastic.

We can mold almost all thermoplastics. For instance, we currently have projects using HDPE, PP, PS, ABS, PPO, PC and work with engineered resins too. Let us know what you need – we are up to the challenge!

This is very common. We can either build inserts for the tool to produce the variations or we can machine (drill/cut/router/weld) the variation. Your volume levels drive the most cost-effective solution.

We can mold in threads. We can also add brass inserts for 8-32, 10-32 and ¼-20 threads (and M4, M5, M6). We have even put Tee nuts from woodworking into some softer plastics.

Our process requires less pressure than standard injection molding. We typically use aluminum tooling, which is less expensive compared to a similar size standard injection (steel) tool.

It is true. The tool has to have the same shut height, use the same material and operate at about the same run rate. This will reduce both your production time and cost.

Yes, we have an in-house paint shop and can paint most materials. We can also add colorant to meet your exact specifications.

We also silkscreen in-house.