Study of Microcellular Injection Molding with Expandable Thermoplastic Microsphere

Abstract Injection molding with expandable thermoplastic microspheres (ETM) containing blowing chemicals is capable of fabricating lightweight, dimensionally stable plastic parts while using less material. This paper presents the study of microcellular injection molding of low density polyethylene (LDPE), polypropylene (PP), and polystyrene (PS) parts with various ETM contents. It was found that the molded parts exhibit relatively better surface quality than conventional foamed parts. The microcellular morphology and cell density of the fractured cross-sectional surfaces were characterized using a scanning electron microscope (SEM). As reflected by the testing results, the cell microstructure – such as cell size, cell density, and a layered structure with a foamed core sandwiched by skin layers – play an important role in the weight reduction, surface quality, and mechanical properties. A smaller cell diameter and a thicker skin layer help to improve the surface quality and tensile properties of the injection molded parts with ETM. Finally, an appropriate ETM content has a positive effect on cell microstructure and weight reduction, whereas too high a concentration of microspheres adversely affects the tensile properties and surface quality.