Introduction to Polycell Foam
Polycell foam, also known as polyethylene foam, is a type of plastic foam that is used in a variety of applications due to its lightweight, durable, and versatile nature. Parts made of polycell foam are created through injection molding.
The closed-cell structure of polycell foam makes it resistant to moisture, chemicals, and UV radiation, and provides excellent thermal insulation and cushioning properties. It is commonly used in the packaging industry for protective padding and cushioning of fragile items during shipping, as well as in the construction industry for insulation and soundproofing.
Polycell foam is also used in the manufacturing of sports equipment such as helmets and padding, and in the automotive industry for sound and vibration dampening. Additionally, it can be found in a wide range of consumer products such as yoga mats, camping pads, and flotation devices.
Applications of Polycell Foam
Some of the most common parts and products made from polycell foam include:
- Packaging materials: Polycell foam is often used as packaging material for fragile items, such as electronics, glassware, and medical equipment. It can be molded into custom shapes to provide cushioning and protection during shipping.
- Insulation products: The material is an excellent thermal and sound insulator, and is commonly used in the construction industry as insulation for walls, floors, and roofs.
- Sports equipment: This material is used to make protective padding for a wide range of sports equipment, such as helmets, elbow pads, knee pads, and shin guards.
- Automotive parts: It is used in the automotive industry for various parts such as seat cushions, headrests, door panels, and instrument panels, as it provides cushioning and sound insulation.
- Medical devices: This foam material is used to make various medical devices, such as prosthetic limbs, orthotic braces, and cushioning for hospital beds.
- Household products: Polycell foam can be found in a variety of household products, such as toys, furniture, mattresses, and pillows.
Overall, polycell foam can be molded into a wide variety of shapes and products, making it a popular choice in many different industries.
Polycell foam is typically molded using a process called injection molding, which involves injecting molten plastic into a mold to create a specific shape. The process involves the following steps:
- Plastic pellets are heated and melted into a liquid form.
- The liquid plastic is then injected under high pressure into a mold that has the desired shape and size of the polycell foam product.
- The plastic cools and solidifies inside the mold, taking on the shape of the mold.
- The mold is opened, and the finished polycell foam product is removed.
During the injection molding process, certain additives such as colorants, flame retardants, or other chemicals can be added to the plastic pellets to improve the performance and properties of the final product. Additionally, the mold can be designed with various surface textures or patterns to create a specific look or feel for the polycell foam product.
Cryogenic Deflashing Polycell Foam Parts
Polycell foam parts can be cryogenically deflashed to remove molding flash. Cryogenic deflashing is a process that involves freezing the parts and then blasting them with a high-pressure stream of plastic media, which removes any excess material or flash left over from the molding process.
Cryogenic deflashing is a preferred method for removing molding flash from polycell foam parts because it is a non-abrasive process, which means it does not damage or deform the parts. Additionally, the process is quick and efficient, and can be used to remove flash from parts with complex shapes or hard-to-reach areas.
Overall, cryogenic deflashing is a popular and effective method for removing molding flash from polycell foam parts, and is widely used in the manufacturing industry to produce high-quality parts with a clean, finished appearance.
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