Trexel, Inc. - Injection Molding: MuCell Injection Molding Process

Introduction · MuCell Process Description · Hardware

The MuCell® microcellular foam injection molding process results in plastic components that are lighter, flatter, straighter, and more dimensionally stable at extreme operating temperatures compared to conventionally molded parts.

The process uses supercritical fluids (SCF) of inert gases, typically nitrogen or carbon dioxide, to create evenly distributed and uniformly sized microscopic cells throughout a polymer. Suitable for injection molding and extrusion, the microcellular foam process enhances product design, improves processing efficiency, and reduces product costs.

Introduction

Microcellular foam injection molding is a process and equipment technology for plastic injection molded components that results in an average cost reduction of 10-25% compared to conventional molding net of all MuCell-related costs.

The microcellular foam process changes the fundamental cost structure of injection molded automotive components through four main sources of economic benefit:

Reduced operating costs through cycle time reductions of up to 50%, reduced scrap rates, and lower energy consumption.
Lower capital costs through the purchase of smaller and fewer machines, and fewer and less expensive molds.
Reduced material costs through component density reduction, thinner design, and material substitution.
The ability to mold thermoplastic parts that are flatter, straighter, and dimensionally improved.

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