Plastics: Structural Foam Molding

ISO 9001:2015 Certified

Our Structural Foam molder produces Thermoplastic, Injection Molded Structural Foam parts from standard and engineered materials. In-house secondary Finishing and Assembly capabilities are available.


  • Lower pressures in the molding process
  • Elimination of sink marks
  • Lower tooling costs
  • Part consistency
  • Allowance of irregular cross sections
  • Additional design geometry stability
  • Able to paint
  • EMI/RFI shielding
  • Can replace heavy metal parts
  • Molded –in or secondary placement of metal inserts
  • Large part capabilities

Structural foam molding is a process using low pressure injection molding with a foaming agent and/or inert gas insertion. The introduction of foaming agent into the melted plastic resin creates walls with a sandwich construction that has a solid skin on the outer layers and a foam core in the center.

This process creates molded parts which are lighter in weight, impact resistant, naturally buoyant, and exceptionally durable.

For Sales and Additional Information please contact:

Mike Staub
10 Braemar Place
Bridgewater NJ 08807
Ph: 908-707-4085

For Engineering and Product Design please contact:

Mark Foyil
601 Route 206, Suite 26-424
Hillsborough, NJ 08844
Ph: 908-431-1221

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• Call: 908-707-4085 or 908-431-1221