Plastics & Injection Molding Manufacturer Blog

Structural foam molding offers an alternative to traditional injection molding. 

Here at Ferriot, we’ve been proud to be a leader in thermoplastic injection molding since the 1940s. Our clients turn to us for professional assistance with contract manufacturing, custom injection molding, painting and assembly. Structural foam molding is another capability we offer when traditional injection molding may not meet part design requirements.  The structural foam process creates parts with a high strength-to-weight ratio and is often used for large parts and in metal to plastic replacement.

Structural foam molding is an option available to manufacturers who are looking for a way to create stronger, more rigid plastic parts.  It is also a method used to reduce potential part weight for larger parts. Almost any type of resin can be used with this type of injection molding. Structural foam  injection molding uses lower pressure and a foaming agent mixed in with the resin. The foaming agent expands within the resin, leaving a dense outer and inner wall with a foam or honeycomb-like center. This cellular core in the part is what contributes to the decreased part weight.  During the expansion process, internal shrinkage or "sink" is reduced which creates a more uniform and aesthetically pleasing part. This process can also contribute to less internal stress in the part with better stability. 

It’s not every day that your company gets featured in a trade publication! It’s even more unique to be worthy of the cover story! The Ferriot team is proud to share with you our BIG IDEAS as they come to fruition.   

Structural foam molding has become a highly evolved technique. Today, thermoplastic resin can be mixed with a chemical blowing agent to expand the melted resin and produce high-strength parts for use in industrial applications. The thermoplastic microcellular structure weighs 10% to 30% less and is stronger and more resilient than traditional injection molded parts.

Perhaps, But It’s Worth a Look To Get the Structural Integrity of Metal or Wood, with Lower Weight and Production Costs