The structural foam molding process is similar to conventional injection molding with the exception that a foaming agent is mixed with the base material. The addition of the foaming agent allows you to mold thicker wall sections with the same amount of material. The process is considered to be a low-pressure form of injection molding. Due to the lower pressures, less clamp tonnage is required. This makes it easier to mold large parts. In addition low pressure molding allows you to use aluminum tooling in place of steel tooling which can save hundreds to thousands of dollars. Structural Foam Molding provides a quality, low stress part molded with an internal cellular structure and a tough external skin.

One of the aesthetic characteristics of structural foam is referred to as "splay". Splay is a white streaking effect that shows on the surface of the part. It is created by the foaming gases coming to the surface and being trapped between the material and the mold wall. In the structural foam molding process the foaming is triggered by the pressure drop that occurs when the material comes from the barrel into a vented mold. This pressure drop initiates the foam action. Sometimes this effect is not wanted and therefore people have the parts painted as a secondary operation. Using a process called Gas Counter Pressure; we are able to eliminate the initial pressure drop so that the material flows into the mold without foaming and the surfaces against the mold freeze. At the end of the cycle, the pressure in the mold is released and the foaming occurs, but only in the core of the part. This process leaves the part virtually "swirl-free" and with an injection molded finish.

In addition to part molding we can also perform a variety of secondary procedures. Remcon can do sonic welding, solvent bonding trimming, assembly, packaging and drop shipping. We provide In-house Engineering services, CAD/CAM design, ISO Quality Assurance and timely product delivery.

Benefits •  Hundreds of Material and Color Choices •  Lower stressed parts than injection molding •  Parts can be sanded and painted •  Pieces can be welded or bonded together •  Lower tooling cost than injection molding

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