Fort Wayne Plastics is a leading custom structural foam molder located strategically in the heart of the Midwest.
The process of low pressure, multi nozzle structural foam molding is the manufacturing molding process of choice for application requirements in which high strength to part weight is critical.
Structural foam molding allows for the injection molding of thick wall parts with the addition of a foaming agent. In order to produce a thicker wall part, a small amount of nitrogen or chemical blowing agent is injected into the plastic material. Under pressure within the injection screw and barrel, the foaming agent does not expand. When the melted plastic enters the mold cavity and core, the foaming process occurs. As the foamed plastic fills the mold, the wall of the part hardens against aluminum mold wall. A thin layer forms a skin structure that is supported by the foamed inner core.
The product choices are virtually endless and span a myriad of industries. Structural foam molding is widely utilized in the material handling industry; plastic pallets, knockdown containers, trays, totes, carts, etc. From a variety of drainage and water filtration applications to lawn and garden, to medical industry uses structural foam molding provides product designers with lots of choices and design flexibility.
Other industries that utilize structural foam molding include building products, transportation, agriculture, recreation, HVAC, marine, furniture, just to list a few.
Structural foam molding and gas assist structural web molding offers a number of advantages including lower cost aluminum molds, multiple parts per shot, material and part recycling and overall durability and strength.
FWP has nine structural foam presses and more than 35 years of experience in low pressure multi nozzle structural foam molding and gas assist structural web molding