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Injection Moulding Process for Lightweight Parts made of Plastic
Warpage and Weight Reduction of Your Plastic Parts
Would you like to reduce the weight of your injection moulded products and thus also contribute to CO2 savings? With ENGEL's injection moulding processes, you can produce high-quality lightweight plastic components. You save up to 20% in weight compared to the compact variants.
Advantages of our Processes for the Production of Lightweight Parts
The requirements for plastic products are becoming more complex. The weight and distortion of plastic parts should be reduced. Mechanical properties such as stability and crash behaviour should remain similar. In weight-sensitive areas such as automotive manufacturing, the total weight of the end product contributes significantly to energy savings. We offer the optimal injection moulding processes for the production of lightweight plastic parts: Foaming technology and glass or carbon fibre reinforced organic sheets.
In foam injection moulding, the plastic mass is foamed in the mould. Part of the material is replaced by gas. This enables a material saving of over 20% for lightweight plastic part compared to a compact component. Less material means lower part costs. The mechanical properties of the component, such as resistance, remain unchanged.
Since foamed lightweight plastic components are partly made of gas, small gas streaks can appear on the component surface during foaming. If you use the right material and apply additional injection moulding processes, the surface of foamed components can be upgraded: The variothermal hot-cooling process gives components more gloss and a superior appearance. Foil back-moulding enables high-quality component surfaces.
Foaming reduces the viscosity of the injected material. The injection process therefore requires a lower injection pressure, which in turn results in lower clamping force requirements. Our tie-bar-less machine series is suitable for the injection moulding production of large lightweight components. Thanks to the larger mould installation space, a smaller clamping unit is sufficient even for large moulds.
Advantages of our Processes for the Production of Lightweight Parts
Lightweight plastic parts with consistent stability
The requirements for plastic products are becoming more complex. The weight and distortion of plastic parts should be reduced. Mechanical properties such as stability and crash behaviour should remain similar. In weight-sensitive areas such as automotive manufacturing, the total weight of the end product contributes significantly to energy savings. We offer the optimal injection moulding processes for the production of lightweight plastic parts: Foaming technology and glass or carbon fibre reinforced organic sheets.
Reduced costs thanks to material savings of over 20%.
In foam injection moulding, the plastic mass is foamed in the mould. Part of the material is replaced by gas. This enables a material saving of over 20% for lightweight plastic part compared to a compact component. Less material means lower part costs. The mechanical properties of the component, such as resistance, remain unchanged.
High-quality surfaces thanks to versatile injection moulding processes
Since foamed lightweight plastic components are partly made of gas, small gas streaks can appear on the component surface during foaming. If you use the right material and apply additional injection moulding processes, the surface of foamed components can be upgraded: The variothermal hot-cooling process gives components more gloss and a superior appearance. Foil back-moulding enables high-quality component surfaces.
Save energy through reduced injection and clamping pressure
Foaming reduces the viscosity of the injected material. The injection process therefore requires a lower injection pressure, which in turn results in lower clamping force requirements. Our tie-bar-less machine series is suitable for the injection moulding production of large lightweight components. Thanks to the larger mould installation space, a smaller clamping unit is sufficient even for large moulds.
Use our know-how for the optimal design of lightweight elements. Reduce your parts costs and save energy. We will be happy to advise you.
Injection Moulding Processes for Lightweight Plastic Parts - an Overview
| Procedure | Product name | Industry | Application | Process |
|---|---|---|---|---|
| Foam injection moulding, MuCell | foammelt | Automotive & Transport, Technical Injection Moulding, Electronics | Interior, structure, logistics, Structure, connector, housing | Produce injection moulded parts with foam structure |
| Gas Injection Technology (GIT) Water Injection Technology (WIT) | fluidmelt | Automotive & Transport, Technical Injection Moulding, Electronics | Oil dipstick, furniture, logistics | Producing hollow bodies by injection moulding |
| Composite / Lightweight construction | organomelt, UD tapes, In-situ, SMC, HP-RTM | Automotive & Transport, Electronics | Structure, engine compartment cover, cover for electronic components | Producing thermoplastic composite components |
| Injection stamping | coinmelt | Automotive & Transport, Electronics | Headlights, light guides, glazing, television housings, covers for electronic components | Produce particularly precise components by embossing |
| Multi-component injection moulding | combimelt | Automotive & Transport, Technical Injection Moulding, Electronics | Interior/Exterior trims | Combining different types of plastic in one component |
Practical insight: Injection moulding process for lightweight components
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![Image shows group of award winners on stage in front of a picture of the Grand Innovation Award]( "The team of project partners involved with ENGEL in the \"Grand Innovation Award\" accepts the award in Bonn. © SPE Central Europe.V.")
SPE honours technological depth and solution expertiseOctober 30, 2025Just ahead of K 2025, ENGEL received four gold awards at the prestigious SPE Automotive Awards. -
![Image shows white and grey WINTEC t-win two-platen injection moulding machine.]( "Compact, powerful, and efficient: The WINTEC t-win 6500 with two-platen technology reduces production costs while ensuring high part quality.")
Efficient Physical Foaming for Interior Applications: WINTEC presents integrated production cell with t-win at K 2025August 21, 2025At K 2025, ENGEL is presenting a state-of-the-art manufacturing solution from its WINTEC brand for interior automotive c ... -
![Image shows a tie-bar-less green ENGEL victory injection moulding machine with automation via an easix articulated robot.]( "Highly integrated production cell for structural lightweight construction: At K 2025, ENGEL presents a compact solution for the efficient production of fibre-reinforced hollow bodies – with reduced material usage, short cycle times and maximum design flexibility.")
Rethinking Lightweight Construction: At K 2025, ENGEL presents a series-ready solution for highly efficient lightweight design with reduced material usageJuly 28, 2025At K 2025, ENGEL will demonstrate the capabilities of its innovative injection moulding technologies for lightweight con ... -
![Image shows dark grey cockpit bicycle handlebars with integrated mountings in lightweight construction]( "ENGEL injection moulding solutions enable advanced functions such as the integration of additional components in a single process step - saving significant time. Image: ENGEL")
ENGEL at EUROBIKE 2025June 2, 2025ENGEL, a global market leader in plastic injection moulding, will be exhibiting for the first time at EUROBIKE, which ta ... -
![Image shows a dark grey bicycle handlebar on a white background]( "Live production of an innovative bicycle handlebar by CANYON Bicycles at the ENGEL exhibition stand")
ENGEL at JEC World 2025February 6, 2025At this year’s JEC World, taking place from 4 to 6 March 2025 in Paris, ENGEL, a global leader in plastics processing te ... -
![Picture shows plasticising unit with gas supply for physical foaming]( "Plasticising unit with gas feed for physical foaming I ENGEL")
Foam Injection Moulding from A to Z at the foammelt Days 2024November 18, 2024On 27 and 28 November 2024, ENGEL will open its doors for the foammelt Days, inviting experts and enthusiasts from the f ... -
![Picture shows the large ENGEL duo 5500 combi M machine with a clamping force of 55,000 kN]( "The large ENGEL duo 5500 combi M machine with a clamping force of 55,000 kN I ENGEL")
Injection Moulding Technologies on a Mega ScaleSeptember 30, 2024The duo 5500 combi M at ENGEL’s Technology Center in St. Valentin -
![Picture shows sustainable and cost-efficient thermoplastic alternative access panels for passenger aircraft]( "Sustainable and cost-efficient thermoplastic alternative access panels for passenger aircraft I ENGEL")
Sustainable and lightweight: efficient production of thermoplastic composite partsJanuary 18, 2024With its many years of experience in injection moulding and its high level of automation expertise, ENGEL develops highl ... -
![Picture shows production of a lightweight plastic element]( "Production of Lightweight Element | ENGEL")
Using Regranulate from Organic Sheet Trimmings in Injection MouldingMarch 31, 2021Thermoplastic composites pave the way for lightweight plastic components to enter the circular economy. With an ENGEL in ... -
![Picture shows plasticising screw from ENGEL]( "Plasticising screw | ENGEL")
New Developments in Thermoplastic Foam Injection MouldingFebruary 28, 2021Lightweight plastic components, energy-saving processing or the combination of several process steps can be combined und ...
 "The team of project partners involved with ENGEL in the \"Grand Innovation Award\" accepts the award in Bonn. © SPE Central Europe.V.")
 "Compact, powerful, and efficient: The WINTEC t-win 6500 with two-platen technology reduces production costs while ensuring high part quality.")
 "Highly integrated production cell for structural lightweight construction: At K 2025, ENGEL presents a compact solution for the efficient production of fibre-reinforced hollow bodies – with reduced material usage, short cycle times and maximum design flexibility.")
 "ENGEL injection moulding solutions enable advanced functions such as the integration of additional components in a single process step - saving significant time. Image: ENGEL")
 "Live production of an innovative bicycle handlebar by CANYON Bicycles at the ENGEL exhibition stand")
 "Plasticising unit with gas feed for physical foaming I ENGEL")
 "The large ENGEL duo 5500 combi M machine with a clamping force of 55,000 kN I ENGEL")
 "Sustainable and cost-efficient thermoplastic alternative access panels for passenger aircraft I ENGEL")
 "Production of Lightweight Element | ENGEL")
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Injection Moulding for Lightweight and Distortion-Free Plastic Parts in Detail
Foam Injection Moulding
With foammelt (MuCell®), you can create distortion-free, lightweight technical plastic parts. The metered propellant gas is released in a controlled manner during the injection moulding process. The foaming process begins. The cell distribution in the foam structure is homogenised once again by a negative embossing process.
MuCell® is a registered trademark of Trexel, Inc.
Gas Injection Technology (GIT) and Water Injection Technology (WIT)
fluidmelt is the perfect option when it comes to forming hollow areas, complex pipe structures or avoiding shrinkage contraction. Fluid injection technology helps you produce moulded parts with greater wall thickness or considerable wall thickness differences without unwanted surface disturbances.
Your Advantages with the fluidmelt Process
Less Material
Less Material
Targeted cavities help to produce in a material-saving and cost-effective manner.
Versatile Application
Versatile Application
For all moulded parts with greater wall thickness and considerable wall thickness differences.
Result
Precise surface
Reduced wall thickness
Injection-Moulded Bicycle Frame with V-frames
In this video, you will see the first injection-moulded bicycle frame made of lightweight plastic components. Made from thermoplastic composites and a hollow, closed tube geometry.
 "Injection-Moulded Bicycle Frame with V-frames")
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Lightweight Construction
The weight reduction and reduction of distortion as well as the replacement of metal in components are the trend today. Functional integration and multi-material design ensure sustainable and economical production. With our innovative injection moulding processes, you can produce lightweight plastic components efficiently and in high quality.
Injection Moulding Process for the Production of Lightweight Plastic Parts
Precision and performance - layer by layer
The laying and consolidation of the tapes takes place in sync with the injection moulding process. A pick-and-place tape laying cell with optical image processing is followed by a consolidation press that can be integrated into the overall process. In this way, we enable a tape lay-up that is precisely adapted to the component geometry, which is followed by the subsequent processes without trimming.
Your advantages with UD-Tapes
Fast, high-resolution camera technology: Errors and inaccuracies can be reliably detected and compensated for.
Experience from our own production: ENGEL uses thermoplastic UD carbon tapes in the production of the e-pic robot series.
Technology centre for lightweight composites: Research and development as well as implementation of customised plant solutions.
Result
High precision despite high ejection rate
In-situ technology opens up new opportunities for the production of fibre-reinforced lightweight plastic components with a thermoplastic polyamide matrix. The application spectrum ranges from thin composite components to highly stressed structural components. Starting from dry, preformed reinforcement textiles, polymerisation and moulding processes are combined here.
Your advantages with in-situ polymerisation
Efficient manufacturing concepts: For fully automated parts production.
Extended range of components: Easy to weld and functionalise.
Tailor-made component design: Fibre reinforcement exactly where it is needed.
Optimum bond adhesion: Thanks to thermoplastic matrix.
Result
Highest precision through servo-electric drives
Excellent process stability due to specially developed software tools
Replace steel and aluminium sheets with lightweight components. ENGEL organomelt is the ideal process for producing components with high stability and the best mechanical properties.
Your advantages with the organomelt process
One-shot manufacturing: Highly integrated, automated thermoforming and injection moulding process for organic sheets.
Saving costs: Cost- and resource-saving production of ready-to-use lightweight construction elements.
Various fields of application: Innovative lightweight plastic technology for automotive parts, portable electronic devices, etc.
Technology centre for lightweight composites: Research and development as well as implementation of customised plant solutions.
Result
Maximum stability thanks to composite technology
Durable bonding of thermoplastic fibre semi-finished products with high-quality plastics
Fibre composite technology with duromer systems
Efficiently manufacture large, stable lightweight components: ENGEL HP-RTM fibre composite technology gives you better shaping and the best properties for large-area parts in the automotive sector. In this process, dry semi-finished fibre products are impregnated with injected resin and then cured under heat.
Your advantages with HR-RTM
Compact production unit: Low overall height and foundation load.
High process reliability: Process monitoring and documentation.
Sophisticated manufacturing: Fully integrated control of the resin injection system.
Clamping units with ENGEL ecodrive as standard and proven ENGEL automation
Result
More efficiency
High quality components
Highest quality and stability for roof systems and body parts.
In SMC technology, a stack of carbon or glass fibre-reinforced, flowable semi-finished blanks is usually processed in a compression moulding process and a heated mould. The ENGEL v-duo machine series features high clamping speeds and active parallelism control. It is the ideal prerequisite for fully automated and precise SMC component production.
Your advantages with the SMC process
Functional component properties: Complex geometries and function integration possible directly on the component.
Fully automated manufacturing: Fully automated manufacturing cells from the semi-finished product to the finished, ready-to-install component.
Paintable components: By using in-mould coating, surfaces of high quality can be optimally prepared for subsequent painting.
Result
Structural lightweight elements with excellent strength values
High performance in automotive lightweight construction
Multi-Component Injection Moulding
Produce innovative moulded parts from different materials in a single work step.
Procedural variants:
Multi-colour parts
Hard - Soft Composites
Thermoplastic - Rubber Composites
Thermoplastic - LSR composites
Assembly injection moulding
Your Advantages with the combimelt Process
One-Shot Process
One-Shot Process
Produce components with up to six injection units that can be controlled simultaneously or sequentially.
Save Space and Energy
Save Space and Energy
Machines for composite injection moulding with short cycle times.
Improving the Design
Improving the Design
The process enables different colour variations and haptic experiences.
Reduction of Process Steps
Reduction of Process Steps
The need for subsequent assembly and printing is eliminated. Different controls are produced in a single cycle.
Result
Superior product features
Varied colour combinations
Additional component functions
Multi-Component Injection Moulding in Practice
Experience combimelt technology at first hand. Integration of design and functionality on a tie-bar-less victory 120 combi injection moulding machine.
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Injection Stamping
Produce precise surfaces for particularly high demands. With the ENGEL coinmelt injection-compression moulding process, you can achieve perfect quality for everything from automotive glazing and optical lenses to moulding the finest, microscaled structures.
Your Advantages with the coinmelt Process
Reduced Clamping Force
Reduced Clamping Force
For optimum melt distribution in large-area components.
Homogeneous Cavity Pressure
Homogeneous Cavity Pressure
Perfect for low-warpage, large-area moulded parts.
Precise Manufacturing
Precise Manufacturing
Active parallelism control of the clamping unit.
Result
Best performance: Highest reproducibility and optimised dynamics
More efficiency: application-optimised equipment packages
FAQ
Impact extrusion is a processing method for sheet moulding compounds (SMC) that has been used successfully for more than 50 years. Especially in the automotive, commercial vehicle, electrical, construction and aerospace industries.
The abbreviation stands for thermoplastic foam injection moulding. Our technology for this is called foammelt.
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