Product novelty 01. August 2024
Foaming large parts by injection molding - sustainable, economical, efficient
The use of chemical blowing agents can be very interesting for manufacturers of large plastic parts, as they can benefit from a number of advantages without having to make a large investment. And these are not just the obvious benefits of reduced part weight and associated material savings.
The less obvious benefits of energy savings, cycle time reduction and improved mechanics are also likely to be of interest. For example, the product becomes more sustainable as less energy is required to produce the item.
Cycle time can be significantly reduced by using chemical foaming agents. The injection time can be reduced as the melt flows better due to the gas dissolved in the polymer. Cooling time can also be significantly reduced because the foam structure means that less mass, and therefore less thermal energy, needs to be cooled.
Other positive effects are that the composite structure of the component increases flexural rigidity. Furthermore, in the event of damage to the component, the foam structure slows crack propagation and reduces the tendency to splinter. The tendency to warp is significantly reduced by the use of chemical blowing agents. Sink marks are significantly reduced or eliminated by the internal gas pressure of the polymer melt.
In summary, foaming of large format components has the following advantages:
- It reduces material requirements and is sustainable.
- It offers significant advantages in the manufacturing process.
- It offers advantages in terms of product properties.
- It is economical.
To achieve the desired results it is sufficient to add the foaming agent to the plastic granules in small dosages (usually 0.5 - 3%). The chemical foaming agent can either be pre-blended with the plastic pellets or – even better – added with a separate dosing unit.
The less obvious benefits of energy savings, cycle time reduction and improved mechanics are also likely to be of interest. For example, the product becomes more sustainable as less energy is required to produce the item.
Cycle time can be significantly reduced by using chemical foaming agents. The injection time can be reduced as the melt flows better due to the gas dissolved in the polymer. Cooling time can also be significantly reduced because the foam structure means that less mass, and therefore less thermal energy, needs to be cooled.
Other positive effects are that the composite structure of the component increases flexural rigidity. Furthermore, in the event of damage to the component, the foam structure slows crack propagation and reduces the tendency to splinter. The tendency to warp is significantly reduced by the use of chemical blowing agents. Sink marks are significantly reduced or eliminated by the internal gas pressure of the polymer melt.
In summary, foaming of large format components has the following advantages:
- It reduces material requirements and is sustainable.
- It offers significant advantages in the manufacturing process.
- It offers advantages in terms of product properties.
- It is economical.
To achieve the desired results it is sufficient to add the foaming agent to the plastic granules in small dosages (usually 0.5 - 3%). The chemical foaming agent can either be pre-blended with the plastic pellets or – even better – added with a separate dosing unit.
Tramaco GmbH
Contact
Mr. Niels Neumann