Keeping up with all of the different injection molding processes that are around can be a challenge. All have distinct features, but you might have a hard time determining exactly which one is right for your products. If you need to manufacture more durable structural components, you might consider structural foam molding, a process that was developed to offer several benefits over other kinds of injection molding for particular applications.

Below, you’ll find some of the most frequently asked questions we get here at KASO to help you learn a little bit more about structural foam molding so that you can determine whether it’s best for your needs.

  • What is structural foam molding? Structural foam molding is a process that’s most often used to produce large structural components. Structural foam molding tends to produce much thicker walls than other injection molded components; as a result, structural foam molded components have a rigid, durable surface. During structural foam molding, an inert gas, typically nitrogen, is mixed with the plastic material before it’s injected into the mold. As the material is injected into the mold, the gas expands and the plastic hardens when it comes into contact with the cold mold cavity. This process makes it possible for durable products to be made with a lower level of pressure than is generally necessary using other injection molding processes.
  • What are the advantages of structural foam molding? One of the primary advantages of structural foam molding is that it is often less expensive than other injection molding processes. This is because structural foam molding uses aluminum molds, which are less expensive than traditional steel injection molds. This makes it possible for manufacturers with low-volume needs to get started with structural foam molding at a relatively low cost.
  • Are there disadvantages to structural foam molding? No injection molding process is perfect, and structural foam molding does have a few disadvantages. The process itself takes longer which means that you will have to invest more time into producing structural foam molded components. It’s important to consider how this extra production time will affect your overall performance and productivity before choosing structural foam molding.


If you have more questions about structural foam molding, make sure you get the answers you’re looking for from KASO Plastics. We are injection molding and engineering experts with a wealth of experience dealing with a wide variety of injection molding processes. For answers to all of your injection molding questions and to get started with our services, contact KASO today.