The Coralfoam process can be applied to virtually all injection moulded parts. It is particularly suited to a core-back process where both thick and thin sections are required; the foaming occurs only in the thick sections, so the cycle time follows the shorter cooling period of the thin sections, the overall part weight is reduced and the thick sections have increased stiffness. The process has been widely adopted within the automotive sector for dashboards, door panels, seat backs, arm-rests and acoustic panels.

The process uses gas in the plastic melt. This gas can be either chemically produced (foaming agent) or physical gas (such as MuCell). We are not competitors to either market sector; we unlock the potential for greater use of their products. We use the gas source in a way that adds considerable value, producing mouldings that are both lighter weight and have a good surface finish.

We differ from conventional foam moulding as our parts have a good surface finish with no ‘swirl’ patterns. The resultant mouldings have a skin-foam-skin sandwich structure where the skin quality matches that of conventional injection mouldings.

Containers and cups also perform well when a Coralfoam ring is moulded around the diameter, increasing hoop strength and providing thermal insulation. Insulated containers using Coralfoam continue to be of interest to customers.

The product pictures show examples of some of the parts manufactured using both the open-mould (early ejection, repeatable expansion) foaming process as well the closed mould and moving core(s) (core-back) process.