Custom Foam Injection Molding Process

J-CAD has a long-standing positive experience of close to a decade in foam injection molding. All of our products are of superior quality. Our experience coupled with recent technological improvements has enabled us to develop our own advanced structural foam injection molding system that produces products of ultra high quality.

Contact us today to have your project quoted by one of our experts.

Design

At J-CAD Inc. we are not specific about the form in which you provide us information about your project design. It could even be hand drawn, we don’t mind. We will convert it to a 3D file required for mold making and injection molding mass production. We will work with you to ensure that the design is optimized for the purpose for which it is intended. Our experienced team of highly skilled designers will help you bring out the best out of your product.

Products made from foam

At J-CAD Inc. we produce a very wide variety of products owing to our diverse customer backgrounds and industries served. Our products include:

  • Automotive products
  • Construction products
  • Furniture
  • Beddings
  • Coating adhesives
  • Footwear
  • Packaging materials
  • Medical applications

Here are some of the latest projects we’ve worked on with some of our clients all around the globe!

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Foam Injection Molding Company

In Foam injection molding, thermoplastic materials are first melted. When the melted plastic is evenly soft, an inert gas (blowing agent) is introduced into the polymer melt to make the solution foam-able. The solution is then injected into a mold to make the foam product.

Process for molding in foam

The visual above is just the basic principle of the foam injection molding process. The quality of the end product is highly dependent on how delicately the foam injection process is balanced which we have mastered at J-CAD Inc. We have done away with stop-and-flow molding because of the resulting inconsistency in gas dosing. We have come up with ways to ensure that there is continuous flow of both the blowing agent and polymer during the injection process. We have also introduced a lot more modifications to ensure that the end products are of superior quality and the cost of our products are affordable.

Foam injection has many advantages including:

  1. Reduced part weight.
  2. Whichever design you have in mind, foam injection will help you achieve it. It is suitable for very complex geometric designs as the foam expands much easier than a solid material,filling the mold cavity much easier.
  3. The end products can be conditioned during production to ensure that they are closed cell, self-skinned and cross-linked.
  4.  The end products are soft. They are very cushioned hence comfortable to handle or interact with.
  5. Foam injection products are aesthetically rich compared to their plastic counterparts.
  6. End products possess a very high strength to weight ratio compared to other products.
  7. Products exhibit more rigidity than a solid part.
  8. The resulting products are easy to clean.
  9. The surfaces of the end products have consistent finish.
  10. Products have a superior impact resistance.

If you don’t feel foam is right for your product (ask us to clarify if you’re not sure) we also have much experience in silicone and plastic injection molding.

Equipment for injected foam molding

Our equipment have been customized to ensure utmost efficiency and cost effectiveness while maintaining superior quality. Our pumps can handle a highly controlled flow rate of a very wide range. They also handle a wide pressure range that is highly regulated.

We have the capacity to handle both physical and chemical blowing agents.

Materials

At J-CAD Inc. we use several polymers for foam injection molding. They include:

Polystyrene

Polystyrene is a synthetic compound, that can be solid or foamed. It is made from monomer styrene and is considered and aromatic polymer.

It is one of the best materials that could possibly be used for foam injection molding.

Polystyrene exhibits the following characteristics;

General purpose polystrene

High Impact Polystyrene

Advantages

  • Ease of melting, fluidity and reasonable setup times making the cycle time substantially short
  • Good surface finish of the final product
  • Low mold shrinkage
  • Inherent thermal stability
  • It is inexpensive

Disadvantages

  • Low impact strength
  • Poor weather-ability
  • Poor chemical resistance
  • It can’t be recycled

Properties

  • It is transparent or white but can be colored
  • It is hard
  • It is brittle
  • Low melting point
  • Exhibit amorphous density of 1.05 grams per cubic centimeter at 25°C
  • Its glass transition temperature is 100°C

Applications

  • Packaging materials
  • Consumer electronics
  • Construction products
  • Appliances
  • Medical applications
  • Toys

Polyethylene

Also known as polyethene, polyethylene is the most commonly found plastic around the globe, with annual production being around 80 million tonnes.

Polyethylene exhibits the following characteristics:

Low Density Polethylene (LDPE)

High Density Polyethylene (HDPE)

Advantages

  • It is inexpensive
  • It is very lightweight
  • It is flexible
  • It is impervious to rot, mildew, bacteria and mold
  • It is non-abrasive
  • Exhibits super strength and tear resistance
  • Possesses excellent shock absorbing and vibrating properties
  • Has no odor
  • Has no CFC
  • It is very buoyant
  • It is very easy to fabricate
  • It can be recycled

Disadvantages

  • Non-biodegradable

Properties

  • Its glass transition temperature is -78°C
  • Its melting temperature is 100°C
  • Its molecular weight is 28.05 g/mol
  • Its amorphous density is 1.00 grams per cubic centimeter at 25°C
  • Its crystalline density is 0.855 grams per cubic centimeter at 25°C

Applications

  • Packaging materials
  • Manufacturing materials
  • Construction materials

Polyurethane

Polyurethane is a polymer that is available in thermosetting (does not melt when heated) and thermoplastic (melts when heated) versions.

Polyurethane exhibits the following characteristics:

General purpose polystrene

Advantages

  • Inexpensive
  • Versatile
  • Lightweight
  • High resistance to mildew
  • It performs well in harsh environments

Disadvantages

  • Exhibits short lifespan
  • It emits odor though very slight

Properties

  • Highly resilient
  • Very flexible
  • Exhibits high load bearing capacity
  • Resistant to abrasion and tear
  • Highly resistant to grease, oil and water
  • Exhibits very good insulation capability
  • Strong bonding properties

Applications

  • Automotive
  • Building insulation
  • Footwear
  • Coatings and adhesives
  • Refrigerators and freezers
  • Furniture
  • Bedding