STRUCTURAL FOAM MOLDING

AND SANDWICH MOLDING

INJECTION MOLDINGTo produce the parts by injecting a material.

Performed with metals, , thermoplastic and thermosetting polymer.

STRUCTURAL FOAM MOLDINGlow pressure injection molding inert gas into the melted polymerReduces density and weightIncreases strength

Materials usedThermoplastic material:

•Polycarbonate•ABS•Polyphenylene oxide-PPO•Polybutylene terephthalate

Design Benefits Reduced part weightThick sections up to 5 inchesLower cost toolingChemical and corrosion resistance

Performance BenefitsIncreased strength to weight ratioChemical and corrosive resistanceImproved acoustical and electrical insulation characteristicsCan be recycled and reused.

APPLICATIONS•Tool boxes•Trash cans•Commercial laundry bins•Pallets•Replace wood,concrete,metals,fiberglass

SANDWICH MOULDINGTwo or more polymers are injected one after another through the same gate in one or more cavities.Core and skin material different or same.Also called as co-injection molding

PROCESSINJECTION 1-FORM THE SKIN MATERIAL

INJECTION 2- FORM THE CORE

INJECTON 3-TO SEAL THE GATE AND FINISH THE PART

PROPERTIES OF SKIN MATERIAL

Will be thin Surface structure of the material.Transparent materialPaintable surfaceE.g.: glass, thermoplastics,

thermosets , sheet material , plywood

PROPERTIES OF CORE MATERIAL

Thick but will be lightweight.Low density materialHigh bending stiffness.Recycled material.E.g. :PVC, polyethylene ,polystyrene ,

metal foams.

APPLICATIONS

•Door handles in car industry(strengthening)

•Electronic housings•Decks in ships•In aerospace, making doors in airplane•Antennas

METHODS:Autoclave moldingAdhesive bondingLiquid moldingContinuous lamination Compression molding