A new approach to creating light-weight plastic parts with good surface finish using tap water to create structural foam mouldings

Structural foam moulded parts have a cellular foamed core with a relatively solid skin outer, produced by a form of injection moulding using a chemical blowing agent or gas such as nitrogen, butane or carbon dioxide. However chemical blowing agents cause ozone depletion & will be phased out under the Montreal Protocol. Gases such as butane & pentane are an inherent fire risk, while N2 & CO2 are relatively expensive to use. In addition structural foam parts suffer from relatively poor surface finish especially when low injection pressure is used. Ours is an innovative new process to make structural foam moulded light-weight parts. It offers up to 40% weight saving, 40%+ cycle time reduction & 30%+ energy savings simultaneously. This project will build on existing international cooperation with key partners and potential users and ensure strong commercial relationships which will aid a successful development of the technology.