With PopFoam, discover chemically resistant with durability that is also soft to the touch. We call it Soft Toughness. Design a complex process in search of a simple solution. Every product exists to either deliver a unique benefit or solve a specific problem.
It's up to designers to use every resource at their disposal to engineer that advantage. Materials must meet unique requirements for performance, size, cost, and production, and complicating matters even further, it's not out of the ordinary for these factors to conflict with each other.
As a result, designers are frequently forced to make compromises and settle for underwhelming options. But as production processes have improved, the applications for PopFoam have expanded far beyond the soles of our feet. PopFoam is a "Pellet to Product" concept, rather than the "die cut" and "compression molded" foam products designers settled for in the past.
It facilitates new design possibilities that prioritize both style and performance. PopFoam feed into the injection barrel of the machine and then melted much like injection molded thermoplastics, however now the differences quickly change. The PopFoam is then injected into the tooling under many monitored conditions time, temperature, pressure and flow rates. The material is then cured in the heated tooling, once the temperature is stable throughout the material the tooling is then opened.
Parting lines and drafts are an integral element of a design.
Structural Foam Molding
PopFoam facilitates a simple draft, split-draft design, or full-radius design to touch on the basic options. Our design team encourages early supplier involvement so we can overcome any potential issues as draft is an important element for both manufacturing success however also overall product ascetics. Designers are made aware of both obstacles and opportunities so issues can be resolved early.
Because the injection molded foam process utilizes self-ejection instead of the mechanical injection of thermoplastic injection molding, one of the most critical design principles is using the correct draft. Most part designs will require a minimum of 5 degrees of draft or radius to self-eject the part. Parts without draft cannot eject from the mold Part designs with a simple draft, split draft design or a full radius design will allow parts to eject from the mold. The ability to capture products with a full loop undercut is easy with injection molded PopFoam, the use of floating cores and mandrels along with the reduced cavity size discussed earlier allows the molded products to self eject over tooling feature to create beautiful undercut features that simply cannot be done with other molding process.
Imagine a design that can wrap over a instrument for protection, the ability to have two components to pop together to create multiple colors and densities, a hallow internal cavity to create cushion or spring back. These tooling features are unique to injection molded foams and allow the designer to create extreme undercuts, deep cavities and internal features that other process cannot. The use of these tooling features can be both linear or radial patterns. From simple geometry to extremely complex geometry without the need for expensive complex tooling.
Overall the part design should have a uniform wall thickness.
Uneven wall thickness can result in sink marks or distortions on the finished part. The minimum wall thickness if in limited areas can be 0. These can be either raised or recessed on the part. For smaller text it is better to use raised details as we can implement them into the tooling cavity by use of a laser to define smaller details. Texture is a great way to enhance the quality and definition of your product. Textures define the appearance of the part, from fun to elegant however they also have an impact of the feel of the product, considering non-skid, grip and overall comfort.
PopFoam has hundreds of stock textures examples, these patterns are on our web site www. SALES: sales gatewaycorp. Share This! PopFoam Design Partnership. PopFoam makes designing great products easier than ever.DeKALB Molded Plastics prides themselves on their ability to offer complete custom molding solutions for your structural foam molded products. From engineering design support assistance, to full concept project management, DeKALB's resources can effectively manage your structural foam needs.
We proudly offer both structural foam molding as well as gas assist molding. Structural foam plastic molding is an injection molding process that utilizes a foaming agent that mixes with the base resin in the polymer melt before being injected into the mold.
Rigid Urethane Molding Foam
The lesser polymer volume requires less clamping pressure on the molds. This is often described as a low-pressure molding process. Additionally, cost-effective tooling solutions can be utilized for these large or multi-cavity molded products. As the foamed plastic flows through the mold, the surface cells burst and a solid skin is formed against the walls of the mold while the core of the part cools to a cellular structure.
Parts may weigh up to several hundred pounds.
Thermoplastic Foams: Processing, Manufacturing, and Characterization
From a conversion perspective, structural foam molding can replace wood, metal, concrete, and fiberglass. It can also have significant advantages in relation to alternative processes such as rotational molding, die-cast, stamped metal, smc, thermoforming, rim, and fiberglass layup The results?
Significant reduction in cost and increases in productivity. The structural foam process allows the 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.
There are numerous benefits to selecting structural foam or gas assist molding. Structural foam molding is an excellent conversion alternative for wood, metal, concrete, and fiberglass. The result is a significant reduction in cost and a vast increase in productivity. The following are the key benefits of structural foam 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. I n gas assist molding, the gas will displace the polymer in thicker areas to hollow out the part.
The nitrogen gas does not mix with the resin but instead forms a continuous channel through the hotter, less viscous sections of the melt stream. The gas maintains internal pressure throughout the cooling cycle. The process is a low-pressure injection method. The gas is then utilized to fill and pack out the remainder of the part.
The nitrogen is typically injected into the process at relatively low pressures. DeKALB Molded Plastics is proud of the world-class quality reputation that it has established in the structural plastics industry. Our team is dedicated to providing products and services that exceed customer expectations with a high focus on continuous improvement. Our high commitment to quality is achieved by adhering to clearly defined standards that help to control all process variables. To ensure all products consistently meet your expectations, our highly skilled team is trained to utilize the most modern methods of quality assurance:.
Discover how structural foam molding can replace wood, metal, concrete, and fiberglass. Download our PDF file today.
Download the PDF file today. What is Structural Foam? Structural Foam Process The structural foam process allows the production of rigid plastic products which have a cellular foamed core surrounded by an outer skin forming a total integral structure. Structural Foam Benefits There are numerous benefits to selecting structural foam or gas assist molding. Key Benefits of the Gas Assist Molding Process Design freedom utilizing thick and thin wall sections Hollow gas channels increase stiffness and reduce cooling time Improved aesthetics low warp, no sink marks, etc.J-CAD has a long-standing positive experience of close to a decade in foam injection molding.
All of our products are of superior quality. Our experience coupled with recent technological improvements has enabled us to develop our own advanced structural foam injection molding system that produces products of ultra high quality.
We will work with you to ensure that the design is optimized for the purpose for which it is intended. Our experienced team of highly skilled designers will help you bring out the best out of your product. Our products include:. In Foam injection molding, thermoplastic materials are first melted. When the melted plastic is evenly soft, an inert gas blowing agent is introduced into the polymer melt to make the solution foam-able.
Polyurethane and Its Use in Injection Molding
The solution is then injected into a mold to make the foam product. The quality of the end product is highly dependent on how delicately the foam injection process is balanced which we have mastered at J-CAD Inc.
We have done away with stop-and-flow molding because of the resulting inconsistency in gas dosing. We have come up with ways to ensure that there is continuous flow of both the blowing agent and polymer during the injection process. We have also introduced a lot more modifications to ensure that the end products are of superior quality and the cost of our products are affordable.
Our equipment have been customized to ensure utmost efficiency and cost effectiveness while maintaining superior quality.
Our pumps can handle a highly controlled flow rate of a very wide range. They also handle a wide pressure range that is highly regulated. They include:. Polystyrene is a synthetic compound, that can be solid or foamed. It is made from monomer styrene and is considered and aromatic polymer. It is one of the best materials that could possibly be used for foam injection molding. Also known as polyethene, polyethylene is the most commonly found plastic around the globe, with annual production being around 80 million tonnes.
Polyurethane is a polymer that is available in thermosetting does not melt when heated and thermoplastic melts when heated versions.
Structural molding shares some similarities with injection molding, but these are the main differences between the two processes:. Flexible polyurethane foams are easy to use and durable, and very efficient for absorbing energy at controlled rates, changing resonance or shock-pulse frequencies and relieving static stress on flexible materials. One interesting fact about flexible foam is that it contours around molds, allowing you to take shapes and make flexible objects that can easily be used for production items.
These are usually produced with silicone molds, but urethane or other molds Keep reading. Another plus with molding in flexible foam is the ability to add color pigments to achieve vibrant colors. Polyurethane foams are made by mixing two-part polyurethanes, that expand upon mixing and fill the molds, allowing for a lot of variety in material density and functionality.
They become very rigid, but are really easy to use and cure, and can be used as a lightweight casting or filling material. This type of resin can also be colored with a variety of additives and is very resistant to most chemicals.FMI utilizes reaction injection molding, casting and foam in place. We mold urethane elastomers, rigid, semi rigid, self skinning and flexible foam. Products range from fuel floats and bumpers, to spa cushions and parts for theme parks.
We complete both small and large assemblies. Our attention to detail, competitive pricing and customer service distinguish us from our competitors. Because of the different applications and formulas, we are limited only by your imagination. Knowing the proper forming and processing techniques helps in choosing one type of processing method over the other.
Further classification of plastic materials or resins, can be used to choose the best technique to form a particular product. While completing both small and large assemblies, we utilize the following processes:. We serve numerous markets. Our products range from fuel floats and bumpers to spa cushions and parts for theme parks. Below are some of the industries represented. We are always interested in exploring new opportunities.
Our molded products are not easily recognized, but they are used in many applications on a daily basis. Our attention to detail, quick turn around times, reasonable cost of molds and our commitment to customer service, helps us to keep you, our customer, our 1 priority.
Our talented staff will work with you to insure that the proper tooling is created to produce your parts. Some molds are top filled and are made from aluminum, epoxy composite and silicone. Molds are made for all processes. Having this in-house capability allows us to save time and get your job into production in a timely manner. We can also store your tooling so it is always on hand for your projects. Please see some examples of tooling below.
Bone growth stimulation We get the opportunity to be involved with some interesting and life changing products. This client produces regeneration products which consist of bone growth stimulation devices that are used to treat non union fractures and as an adjunct therapy after spinal fusion surgery.
This part requires electronic components to be embedded in it, along with several additional assemblies to complete this operation. Head rests and cushions We supply the entertainment industry with many parts.
From elastomer covered aluminum pulley wheels, head rests, bumpers and simulated wood grain bench pads we do it all! So next time you take a ride it might be on us! Environmentally friendly FMS is proud to be associated with companies dedicated to preserving our environment. They manufacture an artificial tree that helps enhance the appearance of our highways and by ways. These trees are actually placed in with a group of palm trees and it is hard to pick them out.
To get the realism needed, attention to detail is once again required. Every part goes through our QC department before it is passed on to a freeway near you! They had some unique requirements. Not only did it have to be bacteria and fungal resistant, but latex and silicone free.Structual foam molding is an injection molding process that creates structrually sound and light weight parts that are less likely to warp.
A foaming agent is mixed with part resin while still in pellet form. As the resin and foaming agent is heated by the barrel and injected into the mold, the foaming agent turns into gas.
Less material is required because the gas bubbles expand until the cavity is filled. As the material pushes against the wall of the mold it creates a thick skin while leaving the inside of the part with a cellular like structure. Due to the unpredictable nature of the gas, structural foam parts have an uneven surface color; you can visibly see tints and shades of the chosen color in a swirl-like pattern. For parts that require high cosmetics, we offer in-house painting services. With our expertise in injection molding and sheet metal fabrication, we can help you convert sheet metal parts to structural foam or form the sheet metal base that supports the structural foam skins in-house.
Structural foam molding is a great option for large, thick parts. It is widely used for medical and industrial products including; medical carts and machines, self-serve kiosks, ice makers, and industrial flooring, bezels, and equipment. Read Now. Tenere's integrated solutions stems from our commitment to seeing our customers succeed.
Structural Foam Molding. Request a Quote. When to Choose Structural Foam Molding Structural foam molding is a great option for large, thick parts. Related Links. Injection Molding Guide Learn plastic injection molding terms and definitions. Plastic Design Tips 6 tips to help engineers better design plastic parts for injection molding Read Now. Brochure Tenere's integrated solutions stems from our commitment to seeing our customers succeed.Savings in weight and material, dimensional stability plus higher productivity are aspects that fire the imagination of developers.
All the more surprising is the fact that injection molding specialists have dealt with the physical foaming of thermoplastics rather hesitantly in the past. Especially in lightweight construction, the MuCell process offers great potential. As soon as the subject of foaming comes up, many experts spontaneously think of reaction technology. Admittedly, this year is the 75th anniversary of the discovery of polyurethane.
Without going into further detail about the wide range of properties and applications of the two very different material groups PUR and thermoplastic foam, the lightweight construction potential that is common to both materials must be mentioned. While numerous applications were found for polyurethanes, FIM failed to achieve comparable successes, although it is one of the oldest special plastics processing technology.
The foam structure, as well as the resulting lower density, only became interesting many years later, since new materials and suitable propellants had to be developed first.
Hereby, the use of a physical propellant seemed to be most practicable, together with the so-called direct gassing as a variant of FIM. The principle was based on introducing the foaming agent under high pressure directly into the melt-filled screw flights.
Applications known from automakers at that time were decorated interior linings, housing parts, and electrical connectors. Because the propellant gases used were no longer permitted for ecological reasons, the project was finally dropped in favor of the chemical process. The first breakthrough was made by Trexel Inc. It was only at the beginning of the year that interest was focused on injection molding.
However, several strategic mistakes prevented a successful propagation of the process: In addition to the costs for the technical equipment, Trexel demanded license fees from users, whereby the amount was determined annually, and was based on throughput.
Since the end ofTrexel no longer charges license fees, but this important information has not yet reached all areas in the plastics industry. Another hindrance was the marketing strategy.
Apart from the original focus on extrusion,Trexel initially failed to address the potential users and OEMs. Consequently, awareness of the new process was mainly restricted to a small circle of insiders. Meanwhile, Trexel has changed their strategy, and has raised the interest of users and OEMs. As one of the first machine manufacturers, KraussMaffei in Munich, Germany, has cooperated with Trexel from the start. Following the joint development of standardized equipment on the machine side, KraussMaffei included complete MuCell system packages in their product range early in Plasticizing Unit With Gas Injector.
In simple terms, this type of physical foaming involves injection molding with gas charging. Prerequisite is a fully automated injection molding machine with screw position control and increased injection volume. A plasticizing unit with a specially designed screw is the heart of the system. The gas is injected directly into the plastic melt in the form of a super critical fluid SCFfrom which the screw produces a homogeneous single-phase solution.
Nitrogen or CO2 is used as propellant Fig. Important hereby is that the melt pressure in the plasticizing unit — and possibly also in the hot runner system — may not fall below the critical SCF melt pressure during the entire cycle.We purchase commercially available raw materials and as a converter, customize them to meet your specific requirements.Kurtz THERMO SELECT Process – Particle Foam meets Injection Moulding!
Having many in-house capabilities allows us the flexibility to assist you with your design, create tooling, and assures that your job is produced in the most cost effective and timely manner. We provide our customers with a high level of customer service, as we find solutions for your requirements.
With product concept in hand, we can create the prototype as well as the necessary tooling for full-scale production. In oursquare foot facilitywe mold polyurethane parts, sheet plastic, and fabricate foams in more ways than any company in the West.
Additionally, we can thermo-form large and small parts as well as production paint plastic, wood, and metal substrates to meet your specific requirements. Our fabrication team offers a wide variety of foam conversion services that will take your project from conception to completion.
With the ability to cut, shape, and thermal form foam into any specification your project requires, we are truly a one stop shop for your custom foam projects. Vacuum forming also offers the ability to provide textured and styled finishes. We use but are not limited to urethane elastomers, rigid, semi-rigid, self skinning, and flexible foams. FMS Automotive offers innovative solutions to create award winning designs for your automotive projects. We manufacture body kits, fender flares, spoilers, running boards, fascias and more.
Partnering with some of the largest OEM companies has given us the experience to work with the best. More About FMS. FMS offers engineering, molding, and fabrication of flexible and rigid foam. More About Our Capabilities. FMS Capabilities. Vacuum Forming. Specialty Molding. Contact FMS. Toggle Sliding Bar Area.