Structural foam molding (SFM) is similar to traditional injection molding in that heated thermoplastics are injected into precision-made tools. The key difference between structural foam molding and typical injection molding is SFM was developed and is capable of producing much larger sized parts with lower molding pressures.

Lower molding pressures are needed with structural foam because inert gases add to the pressure in the mold cavity instead of relying totally on machine pressure. This produces results with a cellular core and solid plastic exterior walls and a part geometry with less internal stress and better stability.

SFM gives product designers and manufacturers great benefits and opportunities to create a variety of custom manufactured plastic products.