Looking for a solution that combines the strength of traditional injection molding with the benefits of lightweight materials? Say hello to MuCell — a game-changing technology designed to deliver robust yet lightweight plastic components.
MuCell isn’t here to replace traditional injection molding; it’s here to enhance it. By introducing innovative foam injection molding techniques, MuCell offers a unique approach to crafting plastics that are both durable and lightweight.
Redefining Excellence in Lightweight Plastic Innovation
Discover the Innovation of MuCell: Lightweight, Strong, and Sustainable
Weight Reduction
With MuCell, you can achieve significant weight savings compared to traditional methods. By injecting inert gas into thermoplastic melts during plasticization, we create a foamed core surrounded by solidified compact edge layers—resulting in lightweight components without compromising strength.
Less Deformation
Tired of dealing with warped parts? MuCell’s advanced foaming technology minimizes deformation, ensuring your components maintain their shape and integrity.
Reduced Sink Marks
Say goodbye to unsightly sink marks. MuCell eliminates the need for chemical blowing agents, resulting in smooth, uniform surfaces with minimal imperfections.
Enhanced Strength
Despite their lightweight nature, MuCell parts maintain exceptional strength and durability.
Reduced Cycle Time
Speed up production and increase efficiency.
Optimized Designs
Achieve optimal wall thickness and intricate designs for maximum performance.
Environmental Benefits
MuCell’s lightweight materials reduce fuel consumption and CO2 emissions, contributing to a greener future.
Technology Details
The MuCell thermoplastic foam injection molding technology is based on simple physical principles. Good homogenization will be achieved by high pressure introduction of inert gas (usually N2 or Co2) into thermoplastic melts during plasticization. When injecting this into a mold, the pressure drop directly after the injection nozzle will result in cell formation. The result will be integral foam – solidified compact edge layers over a foamed core – similar to sandwiched structures.
This will generally save at least 8% of the weight when compared to conventional compact injection molding. Even more weight may be saved with optimized designs of components and molds. Reference may also here be made to processes such as negative embossing strokes integrated into a mold. The change in mechanical properties caused by foaming should be taken into account in the component design.
Expansion of the gas will generate the cavity pressure required to compensate for shrinkage and also, as opposed to standard injection molding, enable production of components with excellent dimensional stability and accuracy that are also virtually free of distortion and pock marks. Since outgassing during the injection process will create flow marks on the surface of components that are not specifically designed and processed for this purpose, such parts require special treatment where they will be visible. These effects may be covered by IMD, or significantly reduced by e.g. variothermal treatment near surfaces or special tool coatings.
Advantages
- Reduced cycle time
- Lower scrap rate
- Reduced warpage
- Wall thickness optimized design
- Less change loops
- Reduced consumption of fossil raw material
- Recyclable
- Reduction of CO2 emission
- Function focused design
- Enhanced component integration
Potential applications
- Automotive Sector
- Air ducts
- Subfloor cladding
- Supports
- Components with lengthy flow paths
- Flat components with stiffening by negative embossing strokes
- Office / Household / Industrial machines
- Packaging
- Semiconductor
Why Choose Techniplas?
Industry Leaders
With over 30 global sites and 3500+ employees worldwide, Techniplas is a trusted name in precision plastic manufacturing.
Customer Satisfaction
Join our roster of 250+ happy customers who have experienced the Techniplas difference firsthand.
Advanced Technology
Our commitment to innovation drives us to push the boundaries of what's possible, ensuring you stay ahead of the competition.
Quality Assurance
Rest easy knowing that our processes adhere to the highest standards of quality and safety, with a focus on sustainability and environmental responsibility.
Ready for the future of lightweight and robust plastics?
Learn more about how MuCell can elevate your products to new heights.
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