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Foaming plastics in injection molding
Lighter, higher quality components with ENGEL foammelt
In thermoplastic foam injection molding (TSG), the melt is enriched with a physical or chemical blowing agent during plasticizing. The blowing agent dissolved in the melt pushes the material against the mold wall and ensures homogeneous pressure distribution. This creates a part with a foamed core surrounded by a solid outer skin, offering numerous advantages for users.
Thermoplastic foam injection molding (TSG) creates a foamed core with cavities and a compact outer surface. This reduces the weight and material usage while maintaining nearly the same excellent mechanical properties of your component.
Physical or chemical foaming generates internal pressure within the part. This effectively counteracts potential warping or shrinkage and prevents sink marks. You achieve highly dimensionally stable parts and reduce scrap. This is essential for components with complex geometries.
Another advantage of foaming plastics in injection molding is the reduced internal pressure within the component. Clamping force and injection pressure can be significantly lowered compared to conventional injection molding. This leads to lower energy costs, a reduced carbon footprint, and less wear on your tools and injection molding machine. For large, flat parts, it is often possible to switch to a smaller injection molding machine.
due to escaping gases. However, visible components can easily be upgraded to high-quality and even functionalized surfaces using the following ENGEL technologies:
Gas counterpressure process
Thanks to our in-house development and manufacturing of plasticizing components, we offer screws specially designed for physical and chemical foaming processes. You benefit from high process stability, optimal melt quality, and increased plasticizing performance.
Thermoplastic foam injection molding (TSG) creates a foamed core with cavities and a compact outer surface. This reduces the weight and material usage while maintaining nearly the same excellent mechanical properties of your component.
Physical or chemical foaming generates internal pressure within the part. This effectively counteracts potential warping or shrinkage and prevents sink marks. You achieve highly dimensionally stable parts and reduce scrap. This is essential for components with complex geometries.
Another advantage of foaming plastics in injection molding is the reduced internal pressure within the component. Clamping force and injection pressure can be significantly lowered compared to conventional injection molding. This leads to lower energy costs, a reduced carbon footprint, and less wear on your tools and injection molding machine. For large, flat parts, it is often possible to switch to a smaller injection molding machine.
due to escaping gases. However, visible components can easily be upgraded to high-quality and even functionalized surfaces using the following ENGEL technologies:
Gas counterpressure process
Thanks to our in-house development and manufacturing of plasticizing components, we offer screws specially designed for physical and chemical foaming processes. You benefit from high process stability, optimal melt quality, and increased plasticizing performance.
 "Andreas Steurer | ENGEL")
At ENGEL, we have many years of experience in foam injection molding and offer a broad portfolio of solutions. We are happy to help you find the right machine concept for your application.
In thermoplastic foam injection molding (TSG), two fundamental processes are distinguished: Physical foaming, using a gas dissolved in the melt as a blowing agent. Chemical foaming, using a chemical blowing agent (CBA).
Our e-foam dosing units precisely inject the blowing gas into the melt, ensuring high repeatability. For larger production setups, multiple injection molding machines can also be centrally supplied via our e-foam XL multi system.
Automotive interior panel manufactured with the ENGEL foammelt process
Creation of various surface structures with the ENGEL foammelt process
MuCell ® screw G25S with TOR10 central ball non-return valve
Fruit crate produced using physical foaming
Nonwoven fabric back-molded with plastic using the ENGEL foammelt process
Gas metering units on the plasticizing cylinder
Metal insert combined with physical foaming
Using variomelt technology increases the quality of visible surfaces
ENGEL foammelt combined with ENGEL variomelt for high-quality visible surfaces
Foamed thermoplastic elastomer
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![Picture shows armature support with low component weight (© Borealis)]( "Plastic foaming and foam injection molding | ENGEL (© Borealis)")
Blog![Wolfgang Kienzl]( "Wolfgang Kienzl")
Wolfgang KienzlDecember 23, 2020Lighter, more dimensionally stable and more economical components thanks to plastics foamingDecember 23, 2020After this blog article you will be foaming - no, not with anger, but with your injection molding machine! Read what adv ...-
technology
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automotive and mobility
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cost effectiveness
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![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 Molding Technologies on a Mega ScaleSeptember 30, 2024The duo 5500 combi M at ENGEL’s Technology Center in St. Valentin
 "Plastic foaming and foam injection molding | ENGEL (© Borealis)")
 "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")
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