This plastic moulding process produces parts with dense skin and formed core. The process allows for a significant weight reduction, with a lower material consumption, while maintaining high rigidity. The process also reduces warpage of the moulded part and prevents sink marks.
Foam moulding is used to lower the weight of components used in vehicles, aircraft, and sports equipment.
Nitrogen gas is injected into the melt before it is injected into the mould. A solid skin is formed, and the mould core is subsequently retracted a few millimeters, which allows the pressurised nitrogen to expand and create a uniform microcellular foam structure. The typical density reduction compared with solid parts is 7 to 10 percent, but higher reductions are possible. The process can be used with most thermoplastic materials.
We have two sample options (see the product pictures):
1. A piece of foamed polypropylene (PP) that is cut, so you can easily see the foamed core. It measures ~8 cm x ~8 cm.
2. A large tray measuring 32 cm x 21 cm.