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Direct injection expanded foam molding (also known as injection molded foam) is a manufacturing process that creates soft foam products direct from a compound into a final product. [1] This process eliminates the steps normally required for die-cutting and compression molding , because it manufactures the foam and the product, simultaneously.
Expanded polyethylene (aka EPE foam) refers to foams made from polyethylene. Typically it is made from expanded pellets ('EPE bead') made with use of a blowing agent , followed by expansion into a mold in a steam chest - the process is similar to that used to make expanded polystyrene foam .
Evaporative-pattern casting is a type of casting process that uses a pattern made from a material that will evaporate when the molten metal is poured into the molding cavity. The most common evaporative-pattern material used is polystyrene foam. [1] The two major evaporative-pattern casting processes are: [1] Lost-foam casting; Full-mold casting
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Syntactic foam, shown by scanning electron microscopy, consisting of glass microspheres within a matrix of epoxy resin.. Syntactic foams are composite materials synthesized by filling a metal, polymer, [1] cementitious or ceramic matrix with hollow spheres called microballoons [2] or cenospheres or non-hollow spheres (e.g. perlite) as aggregates.
Injection moulding (U.S. spelling: injection molding) is a manufacturing process for producing parts by injecting molten material into a mould, or mold. Injection moulding can be performed with a host of materials mainly including metals (for which the process is called die-casting ), glasses , elastomers , confections , and most commonly ...
This process is usually used to produce rigid foam automotive panels. [1] A subset of RIM is structural reaction injection molding (SRIM), which uses fiber meshes for the reinforcing agent. The fiber mesh is first arranged in the mold and then the polymer mixture is injection molded over it. [1]