Benefits of Structural Moulding in Product Development

Injection moulding is becoming more popular to produce parts and products throughout each year.

The numerous advantages of injection molding large quantities of plastic products can also be attributed the widespread use by manufacturers. One of these benefits is the ability to create a wide range parts quickly in large quantities.


Structural foam moulding can be called low-pressure inject moulding. Before the mould can be filled with the melted polymer mix, an inert gaz is used to pump it into the mixture.

The gas is used to drive the polymer inside the mould. It also evenly distributes its density across the mold. This allows the polymer to take the form of the equipment. The gas can also reduce the finished product’s density or weight while increasing its strength.

Once the polymer cools, it forms a solid surface against the walls. Inside, a honeycomb-structure forms the inner structure. This honeycomb structure allows products to lose weight without compromising their structural integrity. It is also effective in preventing shrinking.


1. Better Aesthetics

Structural moulding has enabled the production of intricate and thick parts that are free from depressions and sink marks.

Parts made by structural foam moulding on the other side have a smoother, more uniform surface and can be customized with any texture. This moulding technique is low-pressure, which reduces stress and warpage.

In some instances, this technology can be used for items of higher quality than standard injection molding. You will also notice that the products created with this technology have superior thermal insulation and acoustic properties to those made with other techniques.

2. Strength Improvement

The honeycomb structure that structural foam molds creates has seen a significant increase in strength. It creates parts and products with a high strength to weight ratio that is even better than those created by standard injection molding.

These parts last longer and are more durable than those made using traditional moulding. Parts made from structural foam are less likely to be damaged. They can be used in a broad range of applications. Furthermore, goods created with this method can Replace sheet metal, concrete and fibreglass.

It is important to note, however: The final product created via structural foam molding is often light and robust with a fairly hard surface.

3. Multiple Mould Options

Structural foam molds use less pressure than other large plastic products. Low pressure and forces make it possible to mass-produce large or multiple pieces with fewer tools and equipment.

Additionally, production can be completed in one process at a much lower cost than traditional inject moulding. Although identical moulds cannot be used for standard injection molding, they can be used in this method with aluminum moulds.

Moulds made with aluminium are more durable because they don’t have to be subjected too much pressure during their moulding process.

4. Low Initial costs

Another advantage to structural foam moulding over traditional steel moulding is its ability to eliminate the need for it. Molding can now take place with less-expensive and lighter materials.

Therefore, it has a lower initial cost than traditional injection molding making it attractive for low volume applications.