Engineering Structural Foam for Brandon Medical

A recent development project has showcased the exceptional versatility of Engineering Structural Foam (ESF) within the medical industry with Brandon Medical, an award winning UK-based technology company with 65 years of healthcare experience.

Product issues

Following advances in lighting technology, the company’s attention was refocused onto an existing product which was currently being manufactured in spun aluminium.

Primary research highlighted that the product required updating to take advantage of developments in lighting technology. A complete product redesign was required, with the brief to maximise all opportunities in order to improve the user experience, form and function, using the most cost-effective and advanced manufacturing processes available.

Issues with the original product included high weight content, poor heat dissipation, infection control, processing time and difficulties in assembly.

After careful consideration and feasibility studies, engineering structural foam (ESF) was selected as the preferred option for manufacture.

Engineering structural foam moulding

Benefits of Engineered Structural Foam

Using engineering structural foam provided a number of key benefits, including:

  • Reduction in weight
  • Reduction in heat transfer
  • Elimination of joint and split lines
  • Introduction of anti-microbial additives
  • Reduction in component count to improve the assembly process
  • Improved user experience
  • Reduced costs.


The incredible strength and versatility of Engineering Structural Foam moulding allowed us to create a lower cost product with superior design features.
Peter North, Senior Design Engineer - Brandon Medical Limited

Find out more

We are only to happy to share our knowledge and expertise of all our processes so please contact us if you have any questions.