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Structural Foam Injection Molding
Built for Size, Strength & Efficiency.
Structural foam molding produces large, lightweight components with a solid skin and foamed core — delivering high stiffness, excellent dimensional stability, and lower tooling cost than conventional injection molding at the same scale.
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110+
Presses on the Floor
22-2,100
tonnage
ISO
certified quality

Core Capabilties

When large, flat, and structural is the requirement.

Structural foam is the right process for enclosures, housings, panels, and large structural components where stiffness and flatness are critical. Thick wall sections resist warping and sink even across broad surface areas, while low-pressure molding reduces clamp tonnage and tooling stress — making it a strong choice for large, performance-driven parts that would be costly or impractical to run on conventional injection equipment.

Strength & Performance at Scale
High stiffness in thick wall sections
Thick wall sections deliver the rigidity required for structural and load-bearing applications — enclosures, panels, frames, and covers that need to hold their shape in use and over time.
Excellent flatness on large surfaces
The foamed core resists the warpage and sink that plague large, flat parts in conventional injection molding — maintaining dimensional stability across broad surface areas without expensive process workarounds.
Consistent dimensional stability
Structural foam parts hold their dimensions reliably over the full production run and through the part's service life — including under load, temperature variation, and long-term stress relaxation.
Efficient Manufacturing & Lower Tooling Stress
Low clamp tonnage requirements
Structural foam fills at low pressure — significantly reducing the clamp tonnage required compared to conventional injection molding of the same part. This opens up press availability and reduces energy consumption per cycle.
Extended tool life
Lower injection pressures mean less mechanical stress on tooling per cycle — extending mold life and reducing maintenance frequency, particularly important for the large, complex tools that structural foam programs typically require.
Material & Cost Optimization
Reduced material consumption
The cellular foam core displaces resin throughout the part's cross-section — reducing material usage compared to an equivalent solid injection molded part without meaningful loss of structural performance.
Lighter parts without sacrificing strength
Weight reduction matters for shipping cost, ergonomics during handling and installation, and end-product performance. Structural foam delivers lighter parts while the solid skin maintains surface integrity and load transfer.
Right-sized for large, cost-sensitive programs
For large components where conventional injection molding requires prohibitively large presses or produces chronic sink and warp, structural foam is often the most practical and cost-effective solution available.
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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.

Structural foam is the right choice when your part is large, has thick wall sections, requires flatness across broad surfaces, or when conventional injection molding would require prohibitively large press tonnage. 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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