Structural Foam Technology
cross section of foam

Structural foam has replaced wood, concrete, fiberglass, cast metal and fabricated products in a variety of applications.

Benefits:

• Higher productivity
• Greater design flexibility
• Chemical and corrosion resistance
• Cleanability
• Lower weight
• Lower raw material and manufacturing costs
• Sound deadening characteristics
• Electrical /thermal insulating properties
• HIGHEST STRENGTH TO WEIGHT RATIO compared to alternative manufacturing methods and materials (concrete, sheet metal, metal castings, wood

Structural foam is a low pressure molding process utilizing a molten resin that has been injected with nitrogen gas or a chemical blowing agent. This mixture is injected into the mold, where the gas expands and fills the mold with foam. As the foam flows through the mold, the surface cells collapse. Solid skins are formed against the walls of the mold, while the core of the part remains structurally foamed. Because the outer skin is solid and the center of the wall is foam, the part weight is reduced up to 20%.

Structural foam yields parts that are larger and sturdier than injection molding. The process pressures are much lower than in injection molding, thereby producing parts that are structurally sound, nearly stress-free and have minimal warpage. Parts made are thicker and sturdier than with other processes (doubling the parts' thickness yields parts up to eight times stiffer).

Structural foam is used in many common items you see everyday,

• Shipping pallets
• Industrial containers
• Automotive parts
• Point-of-purchase advertising displays
• Computer component housings
• Recreational equipment
• Furniture just to name a few.