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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.

Important features:

  • 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.

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