There are numerous manufacturing methods for creating a high-quality, long-lasting plastic component. Each production process, including low pressure structural foam molding, has its own unique benefits and applications.

From impacting mechanical performance to lowering stress throughout the component, learn more about how low pressure structural foam molding leads to the creation of better plastic parts from Port Erie.

What Low Pressure Changes During the Process

In low pressure structural foam molding processes, the foam is what does most of the work, expanding to fill the mold as gas is blown into the mold and cavity.

Because of this, clamp tonnage and cavity pressures are greatly reduced compared to injection molding or even standard structural foam molding. Low mechanical loads commonly found with low pressure structural foam molding processes allow for the use of softer metals for the molds, such as aluminum.

Reduced mold wear saves on tooling costs and allows for repeatability, which in turn can make this process extremely cost-effective in the long run when creating a high volume of products.

How Low Pressure Changes Part Performance

Stiffness-to-weight ratio is improved. Components produced through low pressure structural foam molding can see a weight reduction of up to 20 percent, while the stiffness levels increase by around three to four times greater than normal. This makes for a light yet incredibly durable part.

With less pressure inside the cavity of the mold, there is less stress on the part, which leads to improved dimensional stability, less warping or distortion, and improved insulation in components used for housings, panels, or enclosures.

Cost-Effectiveness and Scalability

Low pressure structural foam molding is cost-effective because less material is needed. The process doesn’t require large amounts of heavy materials in order to create strong, lightweight products. Less material means lower-cost tooling, saving potentially thousands of dollars. Energy usage and clamp tonnage are also impacted, which saves both operating and overhead costs.

Scalability is achieved when multiple structural foam molding projects happen at the same time, as manufacturers can add in assemblies and reduce secondary fastening services.

Reductions in Defects and Surface Changes in Low Volume Pressure Structural Foam Molding

The process supports thick ribs and heavy cross-sections, so designers can use complex wall sections without fear of surface changes and defects like sink and voids that are more common in high pressure molding processes.

Additionally, reduced internal stress and a more uniform shrink lower the chances of cracking and long-term creep, even on larger components like trench walls. Reduction in defects relies on proper mold venting and cooling procedures.

Contact Port Erie Plastics for Your Low Pressure Structural Foam Molding Services

Port Erie Plastics has over 70 years of experience in the plastic manufacturing space, and that includes low pressure structural foam molding services.

With decades of experience as a production company and a highly skilled team, we know what it takes to bring high-quality projects to life. Low volume structural foam molding capabilities at Port Erie are highlighted by the ability to create parts up to 7.5 feet in length and shot sizes up to 150 lbs.

Contact us today to learn more about our structural foam molding services.