A Strong, Light and Cost Effective Injection Moulding Process

Structural Foam

Achieve innovative thermoplastic solutions with engineered structural foam moulding


Hallam Plastics was the first company in the UK to install an engineered structural foam press, and we have been continually developing this process, which now sees us working with world-leading manufacturers. Since 1971, we have been at the forefront of innovative thermoplastic solutions and work closely with customers to create strong, durable and lightweight moulded components using engineered structural foam.

We work with customers to design, develop and evolve parts and components utilising the most advanced technologies, polymers and processes on the market; we can offer large shot weight capacity and platen sizes (15kg shot weight and 1,75m x 2.05m platens).

Compared with traditional injection moulding, engineered structural foam (ESF) can deliver greater strength whilst reducing the weight of the plastic moulded part. Engineered structural foam has a superior strength-to-weight ratio seven times greater than that of steel and with thirteen times the rigidity of zinc.

Structural Foam
Structural Foam
Structural Foam


Get creative with engineered structural foam moulding

With engineered structural foam, you can produce plastic parts that incorporate complex curves, bosses, ribs, bosses, or gussets, from a single moulding, which can help drive costs down. It is also possible to create moulded plastic parts and components with thicker wall sections whilst maintaining a lightweight and more durable honeycombed/closed cell structure.

In addition, engineered structural foam injection moulding can be adapted for twin-shot moulding for the production of complex parts from two different polymers, or coloured polymers in a single moulding cycle. By designing in complex features and reducing assemblies down to a single part, manufacturing time is reduced, as well as cost.

Engineered structural foam moulding is increasingly used for applications where wood, concrete, metal, fibreglass and solid plastics are traditionally used. It is ideal for industries such as aerospace and automotive, where increased strength, weight reduction, and design flexibility are required.

Discover the many benefits engineered structural foam moulding can provide

Among the many benefits engineered structural foam moulding offers is its environmental credentials. Using recycled polymers, the foam moulding process uses less energy and raw material than other processes, and once the component has come to the end of its useful life, it can easily be recycled, and because the process uses a gas to create a closed cell structure, less material is used to create parts with a greater wall thickness.

You should contact Hallam to discuss engineered structural foam if:

  • You regularly buy in large volumes of large injection moulded parts
  • Your designers are looking to incorporate complex curves, bosses or product specific features into a plastic component
  • You are looking to increase the strength of an existing component
  • Plastic moulding weight reduction is key driving factor
  • You are looking to combine multiple injection moulded parts into one moulded part
  • You would like to replace an aluminium machined part, or a pressure die-cast component, into a lower-cost plastic part
  • You need to combine two polymers in one machine cycle
  • Your parts are weight or load bearing
  • Your plastic parts are prone to impact loading
  • You need larger injection moulded parts with a lower tooling cost

Engineered structural foam produces cost-effective, accurate high-volume components with excellent quality. If you would like to find out more, discuss your project or would like us to provide a no-obligation quote, please contact us on 01773 531151, or email us at enquiries@hallamplastics.co.uk

We operate worldwide...

As a leading injection moulding company, our expertise stretches out to cross-sector clients across the world.