Explore the Structural Foam Molding Process From Design to Warehousing

Structural foam molding is a manufacturing process that is used to produce large-tonnage products. This process provides companies with numerous benefits, including its cost-effectiveness for the production of large parts, high moldability, and high durability. In this blog, we will walk you through the entire structural foam molding process, from design to warehousing.

How Does the Structural Foam Molding Process Work?


The first process you must complete is the part design. During this process, our plastics engineers will help you design your part for manufacturability and decide on the right materials. Design for Manufacturability, or DFM, is the process of designing parts for easy manufacturing, saving you time and money during the process.

Next, you will need to design your structural foam mold. Again, our engineers will work with you to help determine the best mold design for your product. They take into consideration the specifications of your product, your product’s application, and the material you are using.


The structural foam production process starts by mixing a melted polymer with nitrogen gas and/or a chemical blowing agent. This mixture is then injected into your structural foam mold under low pressure. The polymer then cools as it touches the walls of the mold. Forming a solid exterior with a honeycomb interior leads to a lightweight product compared to straight injection molding.

Secondary Operations

Secondary operations are done after the manufacturing process in order to make sure your products live up to your standards. This process includes assembly, decorating, and fabrication. Some of the most common services include drilling holes, kitting your products, and decorating them through pad printing, heat transfer, and hot stamping. This allows your products to perfectly meet your needs and your application as soon as they get to their final destination.


Finding a place to store your products after production can be difficult. Luckily, at Port Erie, we offer warehousing services for your products. We take your product directly from the production floor to one of our various warehouses or storage facilities. In providing you with warehousing services, you don’t have to worry about finding another partner or paying for transportation, saving you valuable time and money.


Getting your products to their final destinations will end the structural foam molding process. On-time delivery is crucial to the satisfaction of your customers. Port Erie Plastics offers distribution services from our warehousing facilities, including on-time delivery, client reports, EDI capabilities, lot control, and JIT delivery.

Port Erie Handles Your Entire Structural Foam Molding Process

From start to finish, Port Erie is here to tackle your structural foam molding projects. Our team has been in the plastics industry since 1953 and has had the experience needed to take on even the most complex of projects.

Our team has the experience and capabilities to complete nearly any injection molding and structural foam molding project. We pair you with a skilled plastics engineer to ensure your design is the best it can be and that your production process runs smoothly. Additionally, with our secondary operations and distribution and warehousing services, we can be your partner for the entirety of the process.

If you are ready to start the structural foam molding process, contact our team today.

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