Physical Foam Injection Molding Machine

What is Physical Foam?

N2 or CO2 is mixed with molten resin and injected into a mold. The gas in the resin forms fine air bubbles inside the molded product to reduce the weight of the product and improve warpage and sink marks.

The chemical foaming agent is the mainstream method of foam injection molding in Japan because it is easy to use by simply attaching a shut-off nozzle to a standard injection molding machine and the introduction cost is low.

However, in recent years there has been a shift to physical foaming due to the environmental impact of decomposition residues from chemical foaming agents and the difficulty of using recycled materials.

Physical foam injection molding can be applied to a wide range of resins, there are no decomposition residue problems, and the running costs are lower than chemical foaming agents.

MuCell®, developed by the Massachusetts Institute of Technology, and RIC-FOAM, developed by Maxell Corporation and Kyoto University, are two methods of physical foam injection molding.

We are selling the MuCell® and SOFIT injection molding machines, which combine the above methods with our unique screw technology.

The use of MuCell® technology requires a purchase agreement for SCF supply equipment.

Example

Case 1:Improved sledding

Case 2:Fine foam layer

Case3:Manifold gaskets

  • DuPont 33% glass-filled nylon 66
  • Thickness: 2.9 mm, Thin wall: 0.76 mm
  • Reduced cycle time
    (MuCell® molding reduces solidification time by 66%)
    Conventional: 18 seconds
    MuCell®: 6 seconds
  • Reduced mold clamping force (73% reduction)
    Conventional molding: 150Tons
    MuCell® molding: 40Tons
  • Lightweight
    5-20% weight reduction by various processes

Case4:IC Trays

10% weight reduction and 15% warpage improvement while maintaining IC tray performance(PP containing 15% carbon)

Solid

MuCell®

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