Fort Wayne Plastics is proud to announce an employee anniversary. Bob Grimes- Purchasing Manager has been with Fort Wayne Plastics for 23 years. Bob has long been a major component to the success of Fort Wayne Plastics and has held key positions within the organization. Bob began in June, 1991, as a Quality Auditor and has been moving forward ever since.
Congratulations to Bob!
Fort Wayne Plastics is a leader in structural foam molding and structural web molding with close to forty years in business. Fort Wayne Plastics has nine low pressure multi-nozzle injection molding presses with capabilities of up to 150 lb. shot. In addition to structural foam molding, FWP is a viable technical resource for plastic conversion opportunities and new product development. FWP also has a 70,000 + square foot warehouse and secondary assembly capabilities.
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
Structural-web molding technology is a low pressure process
that creates controlled internal hollow channels in parts that increase
stiffness and strength while saving material and cycle time. It can be
performed on the same multi-nozzle, low-pressure injection machines utilized
for structural foam.
To compare with structural foam molding, a process in which nitrogen
gas is injected into the extruder barrel and mixed into the melt to produce a
part with a solid skin and cellular core; structural web injects nitrogen gas through
special polymer/gas nozzles directly into the mold. The result is a solid skin
with hollow thick sections such as structural ribs.
The web process produces a smoother surface finish than
structural foam with a more aesthetically pleasing appearance. Unlike
structural foam, structural web molded parts do not contain the characteristic
swirls on the part surface. Coupled with the advantages of the low pressure
multi-nozzle format; structural web allows for high quality appearance parts
which can be physically large and/or multiple parts able to be manufactured in
The structural web molding process is favorable to other
molding processes due to the lower internal stresses to the part and lack of
sinks. Additionally, structural web molding lends itself to increased design
flexibility along with lower clamp tonnages and lower cost aluminum tools.