Structural Foam and Gas Assist | 20/20 Custom Molded Plastics
NEW – Ultra High Tonnage Injection Molding Division!

For larger parts, or applications with higher strength to weight needs, thicker walls or complex geometries/requirements, we offer low pressure methods of molding. Our molder, 20/20 Custom Plastics utilizes purpose built low-pressure machines for Structural Foam and Low Pressure Gas Assist Molding. These machines require much less clamp tonnage than similar platen size injection machines but typically have very large shot capacities and an accumulator head design.

This process of molding is similar to injection molding. With structural foam the material is foamed (with nitrogen or CFA’s) to both reduce density and fill the mold under low injection pressure. With low pressure gas assist, the process uses nitrogen gas channels instead of foam (typically through larger ribs) to fill out the part. This process can produce surface finishes comparable to traditional injection molding. The foaming or gas can help mold parts that would be difficult to impossible with traditional injection molding, providing some additional design freedoms and more robust geometry. Since clamp pressure is low, the molds are built of aluminum saving significant costs, as well as not requiring complicated and expensive hot runner systems. Multiple molds can be utilized on the platen at one time, and if required different colors can be injected from each of the twin units.

Our conventional injection molding machines range to levels we refer to as “Ultra High Tonnage”. Our principal, 20/20 Custom Plastics expanded on their large part roots as a low-pressure structural foam and gas assist molder and opened a new plant several years ago including what we refer to as an “Ultra High Tonnage” range. The showpiece is an 8,000 ton press with a 325 lb. shot, the largest Cincinnati Milacron machine installed in the county, along with its “little brother”, a mammoth 6,750 ton machine. A fleet of machines in both our Ohio and Indianna plants provides other large Milacron machines from 2,000 to 4,500 tons.

PRI can help you with your large part needs. 20/20 Custom Plastics offers unmatched low-pressure foam and gas assist capabilities and the highest tonnage conventional injection capacity of any molder in the industry, the headquarters and ISO-9001:2015 plant is a “must visit” for anyone considering this process. We have 4 plants on 3 campuses including Ohio, Indiana, and Georgia to serve our diverse customer base.

Our strength is in developing new applications in structural foam for cost savings. We have thrived because of our perfect vision. Our eyes are on the consistent parts we produce. Our focus on the needs of our customers, and our vision is on the future.