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Microcellular Foam Injection Molding

HRF SERIES | PHYSICAL FOAMING TECHNOLOGY

Flagship Model: HRF-200 (200 tons)

0–0% Weight Reduction
0–0% Lower Clamping Force
0–0% Material Savings
Weight reduction depends on part conditions; over 30% achieved in tested cases

Helps reduce sink marks and warpage while improving dimensional stability — PCR-compatible (material validation required).

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Patent M659181 | ISO 9001:2015 | 40+ Years of Manufacturing Experience

HRF-200 Microcellular Foam Injection Molding Machine

What Is Microcellular Foam Injection Molding?

Microcellular foam injection molding precisely introduces a supercritical fluid (SCF), typically nitrogen (N₂) or carbon dioxide (CO₂), into the polymer melt. As the melt enters the mold cavity, uniformly distributed microcells form throughout the part. These cells are typically 5 to 100 micrometers in diameter and occur at high density, reducing part weight, improving dimensional stability, and lowering material consumption without significantly compromising structural function.

Huarong Patented Microcellular Foaming System — M659181

Physical Foaming Injection Unit for Injection Molding Machines

Dedicated Microcellular Foaming Barrel Assembly Shut-Off Nozzle Gas Drive Unit Gas Supply Unit

Process Principle

  1. 1 SCF Injection N₂ or CO₂ is injected into the polymer melt
  2. 2 Gas Diffusion The gas is broken up and dispersed through screw mixing, diffusing evenly into the melt to form a single-phase solution.
  3. 3 Cell Nucleation A rapid pressure drop during mold filling initiates cell formation within the polymer
  4. 4 Solidification The polymer solidifies into a lightweight part with stable dimensions

Key Benefits

Dimensional Stability

Reduces uneven shrinkage, warpage, and sink marks, making the process especially suitable for flat structures and large-area thin-wall parts.

Weight Reduction 15–20%

Reduces part weight without changing external dimensions, improving competitiveness in automotive, electronics, and sporting goods applications.

Material Savings 10–20%

Uses less material per cycle, lowering resin costs and delivering measurable benefits in mass production. PCR-compatible in selected applications and supports material-reduction goals.

Lower Molding Load 30–50%

Lower clamping force and injection pressure may allow the use of smaller-tonnage machines after application validation, while reducing equipment load and energy consumption.

Proven Test Results

Case 1: Plastic Spool Weight-Reduction Test

Plastic spool weighing 318.0 g without nitrogen Without Nitrogen 0g
Plastic spool weighing 316.0 g with nitrogen at 50 kg/cm² +50 kg/cm² Nitrogen 0g
Plastic spool weighing 213.5 g with nitrogen at 150 kg/cm² +150 kg/cm² Nitrogen 0g Weight Reduced 0%
Without Nitrogen: Shrinkage and Warpage With Nitrogen: No Shrinkage or Warpage

Case 2: Bushing Weight-Reduction Test

Bushing weighing 90.5 g before foaming Before Foaming 0g
Bushing weighing 65 g after foaming After Foaming 0g Weight Reduction 0%

Foamed with nitrogen

Process Parameter Comparison

  • Holding Time Standard: 5 sec No Holding Required (0 sec) Holding Position Setting: 25 → 29
  • Clamping Pressure Setting 65 Kg/cm² 20 Kg/cm²
  • Cycle Time Standard Can Be Shortened in Some Applications
View Actual Machine Parameter Screens
Standard injection holding-pressure screen (holding position 25, holding time 5 sec)
Holding Pressure | Standard Injection Parameters
Microcellular foam injection holding-pressure screen (no holding, 0 sec)
Holding Pressure | Microcellular Foam Injection Parameters
Standard injection mold-closing parameter screen
Mold Closing | Standard Injection Parameters
Microcellular foam injection mold-closing parameter screen
Mold Closing | Microcellular Foam Injection Parameters

Comparison with Conventional Injection Molding

Comparison Item Conventional Injection Molding Microcellular Foam Injection Molding
Dimensional Stability More susceptible to warpage and deformation caused by uneven shrinkage More stable and easier to control dimensionally
Holding-Pressure Requirement Required Can be reduced or eliminated
Clamping Force Requirement Higher Can be reduced by 30–50%
Part Weight Standard weight Approximately 15–20% lighter
Material Consumption Fully solid filling Reduced by approximately 10–20%
Cycle Time Standard Can Be Shortened in Some Applications
Equipment Requirements Standard injection molding machine Requires an SCF system and a dedicated plasticizing unit
Surface Appearance Generally better Silver streaks may occur and must be evaluated

Swipe horizontally to view the full table

Industries and Materials

Microcellular foaming is particularly suitable for applications that require dimensional stability while also targeting lower weight and improved material efficiency.

Automotive Components

Instrument-panel carriers, door-panel interiors, and structural brackets.

Consumer Electronics

Laptop housings, tablet rear covers, and structural components.

Sporting Goods, Transportation, and Industrial Parts

Functional plastic components and packaging applications.

Suitable Applications

Flat or Large-Surface Parts Parts Requiring High Dimensional Accuracy High-Volume Parts with High Material Costs Processes Requiring High Clamping Force

Problems It Can Improve

Shrinkage / Warpage / Sink Marks Dimensional Instability Excessive Material Consumption
Side-view comparison of plastic spools: the upper stack without microcellular foaming shows shrinkage and warpage, while the lower stack with microcellular foaming is flat and dimensionally stable
Top | Without Microcellular Foaming: Shrinkage, Warpage, and Dimensional Instability Bottom | With Microcellular Foaming: Flat and Dimensionally Stable

Commonly Applicable Materials

  • PPGood cell-forming characteristics; widely used in automotive and consumer products
  • PC / ABSSuitable for electronic housings and structural parts; foaming ratio and structural strength must be evaluated
  • PA (Nylon)Glass-fiber-reinforced grades are commonly used in automotive and industrial parts
  • Glass-Fiber-Reinforced MaterialsImproves stiffness and dimensional stability; cell structure and fiber distribution must be evaluated
  • PCR Recycled MaterialsFeasible for selected applications, subject to viscosity and material-quality consistency

Material suitability must be evaluated based on appearance requirements, strength targets, and mass-production stability.

Before You Adopt: Situations Worth Discussing With Us First

Microcellular foaming is not suitable for every application. The following conditions require careful evaluation. Our engineering team can help determine technical feasibility:

Parts with Demanding Cosmetic Requirements

Silver streaks, flow marks, or reduced gloss may occur. Parts with demanding cosmetic requirements may require secondary finishing.

Highly Transparent Parts

The cellular structure affects optical clarity, so the process is generally unsuitable for highly transparent parts.

Very High Strength Requirements

For parts with very high strength requirements, the foaming ratio, material grade, and part structure must be validated through testing before mass production.

Low-Volume or Budget-Constrained Projects

Adoption requires integrated investment in equipment, the SCF module, mold modifications, process development, and training. It may not be cost-effective for very small production runs or short-term pilot production.

Adoption Cost Structure

  1. 01Equipment Purchase and Modification
  2. 02Mold Development and Mold Trials
  3. 03Process Development
  4. 04Operator and Technical Training

Not sure whether your product is suitable? Share your requirements and our engineering team will provide an initial feasibility assessment.

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Machine Specifications

The current flagship model is the HRF-200 microcellular foam servo-hydraulic injection molding machine (200 tons). Additional HRF models will be introduced in other tonnage ranges according to market demand.

Item Unit Value
Screw Dimensionmm42
Injection Pressurekg/cm²2285
Shot Volumecm³311
Shot Weight (PS)g / oz283 / 10
Injection Speedmm/sec122
Injection Ratecm³/sec169
Clamping ForceTons200
Tie Bar Distance (H×V)mm505 × 505
Opening Strokemm465
Mold Thicknessmm130–520
Mold Platen (H×V)mm715 × 715
Ejector Strokemm140
Mold Holemm100
Servo MotorkW25
Heating ZonesZones6
Total Heating WattagekW17.57
System Pressurekg/cm²140
Oil CapacityL340
Machine Dimension (L×W×H)m6 × 1.4 × 1.9
Machine WeightTons6.2

Why Choose Huarong Group

40+ Years of Manufacturing Experience

The Huarong, Nanrong, and Yuh-Dak brands provide a comprehensive portfolio of horizontal, vertical, and multi-shot injection molding machines.

System Integration Expertise

We integrate SCF systems, process implementation, and supporting equipment rather than supplying only a standalone machine.

Application Feasibility Support

We evaluate technical feasibility and implementation planning based on your product requirements.

Automation and Smart Manufacturing

The system can be integrated with automation peripherals and smart production-management solutions.

End-to-End Support from Engineering to Mass Production

  1. Technical Evaluation
  2. Equipment Configuration
  3. Process ImplementationMold trials, parameter optimization, and production stabilization
  4. Long-Term SupportTraining, technical consultation, and automation integration upgrades

Certifications

ISO 9001:2015 ARES Certified | Certificate No. ARES/TW/I2311152Q
CE TÜV Rheinland Certified | Certificate No. BM 50318581 0001

Product Video

Would You Like to Evaluate Whether Microcellular Foaming Is Suitable for Your Product?

Whether you are evaluating a new process, pursuing a lightweighting solution, or seeking greater production efficiency, our engineering team can help define your requirements and identify the most suitable technical approach.

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