What is foam injection molding? Foam injection molding, also known as EVA molding, is a manufacturing process that allows you to develop a wide range products. In short, a resin compound is injected into a mold to create a foam product.
However, not all foams are created equally. XL EXTRALIGHT® foam is a closed-cell foam that has a very tight cell structure, a high level of cross-linking and very specific Polyolefin polymers. This specific injection foam is ideal for many different product development projects.
Here are the top 10 reasons why you should use a North American XL EXTRALIGHT® foam injection molding manufacturer to design your next foam injection product.
1-Location: In an era when product quality and local sourcing is important, make sure you use the services of a North American foam injection molding partner. You’ll gain peace of mind knowing that your product is made materials that adhere to the highest level of durability and reliability so that you never have to trade off on performance, compliance and sustainability.
2-Language and time zones: As a foam injection product designer, the time to market for your next launch is critical. Getting support in your language and time zone can facilitate—and accelerate—the entire foam injection molding process. By choosing a North American foam injection molding partner, you’ll benefit from consistent contact and feedback every day, if required.
3-IP protection: Because of today’s aggressive consumer and B2B markets, developers of foam injection products need to maintain their competitive edge. Unfortunately, not all foam injection molding specialists respect confidentiality of projects. In fact, a developer’s unique intellectual property of its newest foam injection products can be compromised if it works with an overseas company that cares little about accountability to customers.
4-100% designed and developed in North America: More and more buyers, whether they are end consumers or B2B clients, are choosing foam injection products that are entirely developed in North America. Working with a XL EXTRALIGHT® foam injection molding manufacturer can guarantee that material, tooling and final product are made in North America, which again, is a seal of quality, performance and commitment to fair labor laws.
5-Long-standing expertise: As no two foam resins are alike, neither are foam injection manufacturers. When you rely on a XL EXTRALIGHT® foam injection molding partner, you know that product will be developed by world leaders with a 30-year proven track record in using the best foam injection process to design products. These experts constantly innovate and can offer the know-how and support you need to complete your project according to your specs, timelines and budgets.
6-Just-in-time delivery: Product developers face constant pressure to hit the market with their innovations sooner. The best North American foam injection molding expert will have facilities and warehouses in several different locations in order to offer just-in-time delivery (JIT). JIT delivery increases product development efficiency and offers many cost-saving opportunities for clients—which in turn can improve their CAPEX ROI.
7-Production capacity: Trusting a foam injection partner’s production capacity is a huge decision, particularly for high-volume jobs with rigid timelines. Apart from just-in-time delivery, a foam injection product developer must ensure that the manufacturer can actually deliver the required volumes. While overseas suppliers tout that they have the capacity for a project, they cannot always turn things around as quicky—especially when you factor in shipping, customers and the like.
8-Transparency: Supply chain transparency is critical. An XL EXTRALIGHT® foam injection molding manufacturer will always let a client know what is happening upstream in the production process and promptly communicate issues should they arise. Transparency should also be equated to finding solutions to the said issues and indicating upfront the impact it will have on the project’s outcome.
9-The right foam for the job: There are several different types of foam material that can be used to design products. However, closed-cell foams, which have a closed-off cell structure so that air and moisture are unable to pass through, are water- and UV-resistant. They are more durable than open-cell foams. Closed-cell foams are also lightweight, yet highly performant. For many applications, injection molding with closed-cell foams are the ideal material to use.
10-Innovative mindset: A cookie-cutter approach to product design will not allow a developer to outpace the competition. North American foam injection molding partners often have a more vested interest in your project, compared with overseas suppliers that act, well, just as suppliers. While the former will provide systematic support before, during and after a product is developed, the latter simply takes the order, produces it, and ships it. For any mission-critical foam injection molding product development project, which type of business relationship would you prefer?
As you can see, there are tremendous advantages to entrusting your next product design innovation to a North American XL EXTRALIGHT® foam injection molding partner. Contact us today for more information.