Ferriot’s experienced engineers are here to guide you through every critical step in your injection molding journey, from concept to completion.

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Structural foam is a manufacturing material which pairs a foamed core with a solid outer layer. It is lightweight and flexible but maintains the good strength and stiffness compared with traditional polymers. Here is a list of the top 6 advantages when thinking about structural foam.

Ferriot’s structural foam molding process manufacturer services extend through final production, complete with custom color, cosmetic finishing, and assembly.

Indeed, the measure of Ferriot’s true capacity is our institutional expertise in resin selection to support innovative solutions.

Our molding experience covers the knowledge of good Design for Manufacturability, a comprehensive understanding of all thermoplastic resin families, and custom injection-mold design expertise. Typically, we stock more than 150 varieties of resins at any given time in our 200,000-square-foot facility, conveniently located to the major markets of the Midwest and East Coast.

With our highly experienced team of engineers, we design and engineer custom structural foam solutions that didn’t exist yesterday (except in the minds of our customers).

As structural foam injection molding process gains increased attention, you may be wondering whether it’s time to replace metal or traditional plastic components with lighter and stronger engineered plastics.

As one of the few “systems houses” in North America, Ferriot can step in at any point in the manufacturing process because our engineering, design, molding, and tooling, and finishing technologies can be applied to products in concept development or at any other stage of production.

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Overall, structural foam molding offers a compelling combination of strength, lightweight construction, cost-effectiveness, design flexibility, and enhanced performance properties, making it a preferred choice for various industrial applications.

One of the biggest challenges in any new product development effort is identifying skilled people who can contribute significantly to the project, including the vendors who support the process. Ensuring the success of a new product demands the freedom to use new materials and new suppliers, as complex design and production challenges arise.

Contact us to discuss the advantages and benefits of a custom design for structural foam-molded components to optimize performance.

Far more than the simple application of additives, the key to success in this molding type is the ability to incorporate structural foam into a custom design.

When the design is just right, the result is high productivity, cost savings, and lighter plastic components that are exceptionally rigid on the exterior and foamed at the core.