MuCell Microcellular Foaming Solutions for Engineered Plastic Parts

Improved Quality & Lower Costs

MuCell® Molding Technology

MuCell® Molding Technology
The most significant plastic processing
innovation in the last 20 years

The MuCell® microcellular foam injection molding process for thermoplastics materials provides unique design flexibility and cost savings opportunities not found in conventional injection molding. The MuCell® process allows for plastic part design with material wall thickness optimized for functionality and not for the injection molding process. The combination of density reduction and design for functionality often results in material and weight savings of more than 20%.

By replacing the pack & hold phase with cell growth, lower stress parts are produced which have enhanced dimensional stability and substantially reduce warpage. Cell growth also results in the elimination of sink marks.

Unlike chemical foaming agents, the physical MuCell® process has no temperature limitation and does not leave any chemical residue in the polymer; making consumer products perfectly suitable for recycling within the original polymer classification  and allowing re-grind material to reenter the process flow.   The numerous cost and processing advantages have led to rapid global deployment of the MuCell® process primarily in automotive, consumer electronics, medical device, packaging and consumer goods applications.

Reduced Costs

  • Reduced resin consumption  
  • Faster molding cycle time 
  • Increased yields 
  • Smaller molding machine
  • Use of lower cost filled polyolefin materials

Design Freedom

  • Thin to thick wall flow 
  • 1:1 wall thickness rib structure 
  • Material where needed for function versus flow   
  • Improved dimensional stability 
  • Less warpage


  • Reduced petroleum based material consumption 
  • Reduced molding machine energy consumption
  • Ability to re-grind / re-use molded parts 
  • Reduced carbon footprint versus solid molding

Faster to Market

  • Fewer tooling iterations
  • Predictable molded part geometry
  • Ability to mold large partgle piece


  • "The new Golf VII is different: The Instrument Panel retainer is molded with the MuCell process, significantly reducing weight.  A welcome side effect: improved dimensional stability due to reduced residual stress in the part."

    Dr. Roger Hillert
    Head of Polymer Group
    Volkswagen AG

  • Hoffer

    "Trexel has made it very easy. They have a very easy point of entry and they're easy to work with. They helped us tremendously from an equipment and design standpoint and have been here around the clock to support us on any issues that we've had."

    Mr. Jack Shedd
    Vice President of Sales and Marketing
    Hoffer Plastics Corp.

  • Nissei

    "MuCell technology permits improvements in part accuracy...process environmentally clean...applications...wide ranging fields...automobile, home appliances, IT, office Automation industries"

    Hozumi Yoda

  • Nissei

    "We have incorporated the MuCell processing technology into our manufacturing process for over 4 years now and that has allowed us to customize our designs to offer premium cushioning with a reduced amount of material. We have found the durability of these components exceeds standard foam running shoe applications – offering a longer wearing shoe with more rebound and energy return to our customers."

    Katherine Petrecca Strategic Business Unit Manager
    New Balance