As a manufacturer, opting to use foam as your product’s material of choice. Foam is a versatile technology that can be used to create complex shapes, high-quality finishes with contrasting surface textures in a wide range of colors. It also offers a myriad of great properties including being lightweight, affordable, durable, impervious to water and easy to clean. Foam is particularly conducive for products in the spa, pool, watersports, medical and other applications.
But did you know that not all foam-based production processes are created equally? Let’s compare the benefits that foam injection molding using XL EXTRALIGHT® technology outmatches polyurethane foam injection molding and polyurethane compression molding.
XL EXTRALIGHT® foam injection molding versus polyurethane foam injection molding
Polyurethane foam injection molding uses open-cell foam, which means the foam has small cells that are not completely closed. On the other hand, XL EXTRALIGHT® foam is made of closed cells, which are entirely sealed off.
The main difference between open cell and closed cell foams is the firmness. Open cell structure is filled with air which impacts a lot the performance of the foam.
One of the biggest disadvantages of polyurethane open cell foam is durability. As soon as the outer layer of the cells is damaged or destroyed water can enter and bacteria can easily develop. Foam with Closed cell, like XL EXTRALIGHT®, guarantees that products stay 100% waterproof and remain bacteria free event if the surface is damaged. XL EXTRALIGHT foam injection molding is better for products that need to be durable in a water environment.
Products made from traditional polyurethane foam injection molding processes were recognized for their softness and comfort. However, it is important to note that XL EXTRALIGHT® foam injection molding offer a wide range of hardness levels for equivalent density. This allows them to create closed cell based products that are equally as comfortable as those made with open-cell foam.
Furthermore, contrary to polyurethane foam, XL EXTRALIGHT® foam injection molding ensures no bubbles at the back of the components. The benefits of this are threefold:
- XL EXTRALIGHT® foam products have a better chemical resistance.
- They also have a nicer finish and texture.
- Light colors, XL EXTRALIGHT® foam doesn’t tend to yellow, which impacts the long-term look of products.
XL EXTRALIGHT® foam injection molding also varies immensely when compared with polyurethane compression molding. In addition to the aforementioned differences, injection and compression molding are two vastly different processes.
With foam injection molding, thermoplastic materials are evenly melted before injected into a mold to create the foam product.
During compression molding, the thermoplastic materials are melted and then placed in a machined tool that is mounted on a molding press. The mold is then closed to force the polymer solution to come into contact with the mold surface. Pressure is maintained and the material is left to cool. On most products and components, the finished product needs to be trimmed or cut.
Due to the inherent processes, foam injection molding inevitably creates less waste in terms of the polymer solution and scraps. Also, foam injection molding offers superior mechanical properties and quality surface areas that are much more homogenous than compression molding. In the end, products made using compression molding may experience accelerated wear or changes in the surface quality in various zones. Foam injection molding also allow a higher definition of logos, brand imagery and textures even if the they are particularly fine or detailed.
As demonstrated, for many applications, XL EXTRALIGHT® technology EVA foam is clearly more suitable than polyurethane foam injection molding and polyurethane compression molding.
And remember, if you select an EVA foam injection manufacturer in North America as Foam Creations, you also benefit from:
- fast service
- just-in-time production
- fast delivery
- minimal taxes and tariffs.
XL EXTRALIGHT® foam injection molding also varies immensely when compared with polyurethane compression molding. In addition to the aforementioned differences, injection and compression molding are two vastly different processes.
With foam injection molding, thermoplastic materials are evenly melted before injected into a mold to create the foam product.
During compression molding, the thermoplastic materials are melted and then placed in a machined tool that is mounted on a molding press. The mold is then closed to force the polymer solution to come into contact with the mold surface. Pressure is maintained and the material is left to cool. On most products and components, the finished product needs to be trimmed or cut.
Due to the inherent processes, foam injection molding inevitably creates less waste in terms of the polymer solution and scraps. Also, foam injection molding offers superior mechanical properties and quality surface areas that are much more homogenous than compression molding. In the end, products made using compression molding may experience accelerated wear or changes in the surface quality in various zones. Foam injection molding also allow a higher definition of logos, brand imagery and textures even if the they are particularly fine or detailed.
As demonstrated, for many applications, XL EXTRALIGHT® technology EVA foam is clearly more suitable than polyurethane foam injection molding and polyurethane compression molding.
And remember, if you select an EVA foam injection manufacturer in North America as Foam Creations, you also benefit from:
Need more information about our foam injection molding approach? Contact us today!