Polyurethane structural foam is a lightweight, durable material created by injecting a two-part thermoset polyurethane resin into a mold. The chemical reaction produces a foam core with a solid surface skin that can be seamlessly in-mold painted. Known for its exceptional strength-to-weight ratio, structural foam is ideal for manufacturing large, complex parts requiring durability and reduced weight.
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Structural foam parts are extremely lightweight ' typical weights vary from 55 pounds per cubic foot to a mere 2 pounds per cubic foot. In addition to this decrease in weight, structural foam is strong, durable, and extremely stiff ' in fact, up to 8 times stiffer than similar materials such as solid polymers. The modulus of the material increases along with its density, up to a fantastic 250,000 psi. In addition to this, since it is a foam, the material makes for a great thermal and acoustic insulator.
Structural foam is also highly moldable; it is able to produce variant wall thicknesses across a single part. In some cases, structural foam has even been able to generate wall thicknesses greater than the previous maximum of ½ inch (13mm). It also allows for thick ribs and bosses and reduces the risk of 'sinks' over ribs or heavy cross-sections due to the lower viscosity of the mixture. Structural foam products experience less stresses overall during the molding process, and are highly resistant to warpage or deformation.
In addition, structural foam retains the impact, element and temperature resistance common to thermoplastic and thermoset polymers. It experiences minimal to no thermal expansion, making it perfect for products which will be utilized in a wide variety of climates or temperatures. The acoustic and sound dampening properties of structural foam are also superior to those of standard solid polymers.
Structural foam molding is also a highly cost-efficient process. Lower pressures and clamping forces are required during the injection and curing periods, allowing the tooling and molds to be made from lower cost materials such as aluminum. Cycle times are competitive with those of injection and reaction injection molding, making this a time-saving process as well as a money-saving one.
Structural foam products have a lower than average risk of damage in the mold or during the removal process, making it a highly efficient and easily repeatable method. In addition, structural foam produces no potentially harmful styrene fumes, lowering the health risks for workers involved in the molding process.
Lastly, structural foam also features highly paintable, aesthetically pleasing surfaces. In-mold painting (IMP) is possible for all structural foam products, further saving time and money. Multiple colors can also be applied to a single part in-mold. The surface is easy to clean and can be sawn, screwed, nailed or stapled without experiencing any problems.
Structural foam molding is a plastic manufacturing method that is used to create cost-effective, large-tonnage plastic products. During this process, nitrogen gas or a chemical blowing agent is mixed in with a melting polymer. This polymer mixture is then injected into a mold under low pressure. As the plastic touches the walls of the mold, it cools and solidifies, creating a product with a solid outer layer and a honeycomb-like interior.
The process of structural foam molding yields many benefits to both the manufacturer and the customer, including saving time and money on the process. Read on to explore many of the benefits this manufacturing process can offer if you need a large-tonnage plastic product.
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If you have a large-tonnage plastic part or product that needs to be manufactured, the structural foam molding process may be the best option for you. Since the process is a low-pressure process, it requires less clamping force, allowing you to create tooling and molds from more cost-effective materials, such as aluminum. Additionally, the low-pressure process leads to less damage, meaning you don't have to spend more time or money on rerunning machines.
The low-pressure characteristic of the process makes the structural foam very easy to mold. Structural foam molding puts less stress on the product during its production, so it experiences significantly less damage than parts created through straight injection molding. With the reduced risk of damage, you can easily design and create a more complex mold that will maintain the desired shape of the finished product.
The low-pressure process also prevents warpage. There is less stress on the product during the production process, so it is less likely to warp or become damaged while being manufactured.
In addition to its ability to produce very large parts with ease, it is also possible to run multiple molds at the same time on the same machine with structural foam molding. Since it is a low-pressure process, these molds can run simultaneously without putting too much stress on the machines or the molds. Being able to run multiple molds at one time can save you both time and money on your manufacturing process.
Structural foam molded products have many desirable physical properties that make them ideal for use in many industries. These products have a high-strength-to-weight ratio, meaning they are lighter weight than straight injection molded, solid plastic products while still maintaining their strength and durability. They also exhibit good thermal stability and are able to withstand thermal expansion so they will not warp or lose their properties when exposed to extreme temperatures, making them ideal for hot and cold environments.
At Port Erie Plastics, we have been manufacturing high-quality plastic products and parts for various industries for more than 70 years. With our combined 615,000 square feet of manufacturing and warehousing space, we have the ability to take on any of your plastic manufacturing projects.
Our structural foam molding capabilities allow us to produce polyethylene or polypropylene parts up to 7.5 feet in length and with a wall thickness from 0.200 inches to 0.500 inches. In addition to our structural foam molding capabilities, we also have the equipment needed to complete custom injection molding and automated injection molding, allowing us to take on all of your plastic manufacturing needs.
We don't stop there, either. Our in-house team of engineers can help you make sure that your design is optimized for manufacturability. We also offer in-house mold and tool building so you can easily alter your design to make your production more efficient. Once your project is complete, we can warehouse your finished product if needed.