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Gas Assist Molding
Structural Strength Meets Smart Efficiency.
Gas assist molding injects pressurized nitrogen into the melt to hollow out thick sections — delivering superior surface finish, reduced weight, and elimination of sink marks on cosmetically critical parts where conventional molding falls short.
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Zero
sink marks on cosmetic surfaces
Lower
clamp tonnage vs. solid
In-House
finishing & assembly

Core Capabilties

Strength, appearance & efficiency.
Who says you can't have it all?

Gas assist molding balances performance and cost by reducing material while simultaneously improving surface quality. It enables designs — thick structural sections with cosmetically clean surfaces, hollow channels within complex geometry, large parts with lower press tonnage — that are difficult or impractical to achieve with standard injection molding alone.

Uncompromised Performance & Structural Integrity
Internal tubular channels for strength
Gas-assisted coring forms hollow channels within thick sections — improving structural rigidity through the same principle as a hollow structural tube, which is inherently stiffer than a solid section of equivalent weight.
Thick sections without warping or sink
Pressurized gas packs out the part from the inside — eliminating the differential shrinkage that causes sink marks and warp on thick ribs, bosses, and wall sections in conventionally molded parts.
Structural performance with optimized geometry
Gas assist enables part geometries that balance structural performance with material efficiency — thick where strength is needed, without carrying the weight and material cost of a fully solid cross-section throughout.
Efficiency & Material Optimization
Reduced weight through gas-assisted coring
Hollow channels reduce part weight meaningfully — lowering shipping cost, improving handling ergonomics, and reducing the total resin consumed per part across the full production run.
Lower material usage without compromising strength
Gas displaces resin in sections where solid material contributes little to structural performance — concentrating material where it matters and reducing where it doesn't.
Regrind incorporation
Thermoplastic regrind can be incorporated into gas assist programs where application requirements allow — reducing material cost and waste without affecting the structural or cosmetic performance of the finished part.
Quality & Compliance Comes Standard
Cosmetic surface finish without secondary operations
Unlike structural foam, gas assist produces a smooth, glossy as-molded surface suitable for cosmetic applications — eliminating the need for painting or texturing to achieve an acceptable appearance on visible parts.
Finishing and decorating when appearance demands it
For programs where painted, hydrographic, or decorated finishes are required, PSI's in-house finishing capabilities integrate directly — delivering appearance-ready parts without adding an outside vendor.
RoHS compliant and globally accepted materials
Materials used in PSI's gas assist programs are RoHS compliant and widely accepted in global markets — supporting regulatory compliance for medical, electronics, and consumer product applications without additional qualification burden.
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Not sure which process is right?

Injection molding vs. structural foam vs. gas assist – we’ll help you choose what’s right.

Gas assist is the right choice when your part has thick sections with cosmetic surface requirements — where sink marks are unacceptable and painting isn't the answer. It's also well-suited for handles, frames, structural profiles, and parts where hollow channels improve stiffness-to-weight ratio. Talk to our engineering team and we'll tell you which process fits your program.
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The PSI Difference

Partnership From Day One

From the first design conversation to final assembly, our team works alongside your team at every stage. Engineering, molding, decoration, and assembly all happen under one roof, with a single team accountable for quality, timing, and consistency from start to finish.

No handoffs to outside vendors. No gaps in communication. Just experienced people who know your part, understand your standards, and are invested in getting it right.

Less guesswork.

No surprises.

Better Outcomes.

PSI asks questions before  a tool is cut — what does this part need to do, where does it live, what can’t it fail at? Our engineers work alongside yours from day one, so the people building your parts are in lock step with the people who designed them. Good engineering shouldn’t feel complicated. It should just feel like it works.

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Mold Transfer capabilities

Already have tooling? Transferring to PSI is easier than you think.

PSI has a proven process for qualifying and transitioning molds from other suppliers — minimizing disruption to your program while improving the quality, service, and cost structure of your molded parts. Whether you’re reshoring, consolidating suppliers, or simply looking for a better partner, we make the move straightforward.

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