Reduced part weight and increased mechanical properties

Physical foaming is a process used in injection moulding to produce lightweight plastic parts with stronger mechanical properties. It involves introducing a gas into the polymer melt to create small, evenly distributed bubbles throughout the material. These bubbles reduce the density of the plastic, resulting in a lighter weight part, while also improving its stiffness, strength, and thermal insulation properties. Dissolving the gas also reduces the melt viscosity, making it even easier to fill thin-walled components. This technology is widely used by the automotive, packaging, and construction sectors, where lightweight and strong plastic parts are in high demand.

  1. Induction of the gas into the plasticising unit
  2. Gas absorption and diffusion inside the thermoplastic mass
  3. Injection
  4. Pressure drop inside the the cavity initiates gas expansion and foaming
  5. Cooling
  6. Mould opening and part ejection
  1. Plasticising unit adapted to MuCell® technology, including special plasticizing screw
  2. Shut-off nozzle
  3. Gas dosing unit (MuCell®)
  4. Gas injector (MuCell®)
  5. Fully-integrated peripheral devices in the machine control
  6. Safety setup
  1. Part weight reduction up to 40%, depending on the application
  2. Reduction of sink marks and warpage
  3. Reduction of the clamping force/required machine size
  4. Reduction of the injection pressure required to fill the mould cavity
  5. Energy saving through reduced cycle and cooling time
  1. Automotive industry (housings, covers, structural components)
  2. Consumer industry (housing components)
  3. Packaging industry (containers, lids, etc.)