Most any thermoplastic material can be used in a structural foam application including: • Polycarbonate • Polyphenylene Oxide - PPO (Noryl) • Polybutylene terephthalate - PBT (Valox) • Acrylonitrile Butadiene Styrene – ABS

Structural Foam Molding is a process where the addition of a blowing agent and modification of process parameters creates a sandwich construction that has a solid skin on the outer layers and a foam core in center.

Gas counter pressure is a process within structural foam molding whereby the mold is pressurized prior to injection offering these benefits: • Allows the product to have the benefits of structural foam without paint • In mold texture possible • High gloss possible • Makes very flat, dimensionally stable parts

• Lower internal stress than injection molding • Thick ribs and bosses are possible • Brass inserts can be used for threaded bosses • Solid look and feel with a reduced weight and cost • Product is almost always painted • Slower cycle time than standard injection molding

In the structural foam molding process a blowing agent creates a cellular structure while a rigid skin forms. The wall thickness ranges from 0.080" to 0.500" with typical thickness between 0.230" and 0.250".

• Increased stiffness to weight ratio • Reduced part stress • Better heat insulation • Improved acoustical characteristics • Improved electrical insulation characteristics

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