Microcellular Foaming Injection Molding Machine
Introduction
Since the technology of plastic injection molding is well developed, the way to stay compete in the market is optimizing the production process. FCS analyze how Microcellular Foaming Injection Molding (MuCell) process assist the plastic production, such as reducing the weight of plastic parts, shortening the molding cycle, improving the strength, or product lifetime.
Video Microcellular Foaming Injection Molding Machine
FCS has been developing MuCell micro-foaming applications and key process technologies since 2015. By equipping injection molding machines with MuCell screws and gas injection systems, FCS has successfully validated and sold over 40 systems across different machine series, including LM (two-platen), HT (toggle hydraulic), FA (advanced servo), CT-e (all-electric), FB(multi-component), and SA(short-stroke outward toggle)The company continues to assist customers in developing and testing new MuCell applications.
Photo : MuCell system
Advantages of MuCell Foaming Injection Molding
- Product Lightweighting: Through micron-sized foam with uniform cell structure to decrease the density and weight of product.
- Dimensional Stability: Elimination of sink marks and less warpage enhance product flatness, roundness and dimensional stability.
- Heat Insulation/ Noise Reduction: Utilize high-density foaming to achieve the possibility of heat and sound insulation.
- Comfort Fit and Rebound: Physical foaming well distributed within elastomers, achieves impact absorbed and high rebound.
- Energy-Saving: It can reducing Injection pressure, clamping force, holding time on every cycle time.
MuCell Video by courtesy of Trexel Inc. (www.trexel.com)
The Comparison Between Physical Foam (MuCell) and Chemical Foam
Under the drive of lightweight and environmental awareness, using new technologies to reduce the product weight and the impact on environment has received increasing attention. “Microcellular Foaming Injection Molding” application is one of the important developments. The technology of physical foaming is becoming mature enough to replace chemical foaming, which can achieve the ideal results by adjusting the process parameters, and at the same time, it can also solve the problem of sink mark caused by uneven foam cell size.
| Chemical Foam | Physical Foam (MuCell) | ||
|---|---|---|---|
| Mechanical Strength | Unstable | Extremely good | |
| Foam Dimension | Difficult to control | Adjustable | |
| Foam Density | Difficult to control | Controllable | |
| Scope of Use | High temperature plastic materials only | Applicable with more plastics materials | |
| Chemical Substances | Poisonous chemical compounds | Natural gas- N2 | |
Applications
Further Reading >> How to realize lightweighting but high-strength production?
