Structural foam injection moulding generates weight and cost efficiency

Fried is the leading specialist in the development and production of structural foam components. Components weighing up to 35 kg can be produced on machines with a locking force of up to 32,000 kN. The tools with a weight of up to 60 tons are manufactured in cooperation with the international tool manufacturing partners. In the structural foam process, a blowing agent is added to the plastic, which releases a gas at the processing temperatures, usually CO2. Pressure, temperature and injection speed
are adjusted to the production process in such a way that the wall thickness of 5 to 8 mm is achieved: An almost solid edge layer of 1.5 to 3 mm surrounds a foamed core zone of 1 to 4 mm thickness. The result is an integral foam with a lower average density than usual injection moulded parts – without sink marks. The cellular structure of the inner core contributes only a little to the weight, but allows a high stiffness and strength of the component. In addition, the cell structure is capable of absorbing impact energy and noise.

The structural foam process reduced the weight of the component by 70 % (see pictures).

In order to achieve electrical conductivity or shielding against electromagnetic waves, the plastic is partially coated with a copper conductive coating. The functions of the component can thus be maintained with lower weight and material costs.