Engineered Structural Foam Moulding (ESF)
Normally used for medium to high volume production, engineered structural foam (ESF) mouldings are produced on injection moulding machines where a foaming agent is added to produce mouldings with a hard outer surface and softer inner core. These mouldings are tough and unlike injection moulding, thick internal wall sections will not normally produce external sink marks.
- Allows great design and processing flexibility.
- Fast cycle times coupled with high definition parts.
- A high strength to weight ratio with excellent torsional stiffness.
- High impact strength and dimensional stability.
- Reduction in secondary finishing operations.
- Aluminium tooling is generally suitable and can be coupled with the innovative use of multi cavity tools.
- Possibility to integrate details to simplify assembly.
- Components can be manufactured with a general 4mm wall thickness.
- Most thermoplastics can be formed. Noryl, ABS, Polystyrene and Polycarbonate are popular and foamed versions have similar shrink rates.
- Mouldings can be manufactured to meet UL94V0 flame retardency.
- Recycled materials can be utilised.
- Parts normally require painting and can be RFI shielded.
- Rimplas moulding machines range from 60 tonnes to 800 tonnes.