Foam Filling

Rotational molding foam filling is a secondary process that involves injecting a polyurethane foam into the hollow cavity of a rotomolded part. In addition, rotational molding foam filling is used in a wide range products such as ice coolers, buoys, refrigerator components, and reinforced structural components.

Roto Dynamics offers a range of services for your rotational molding needs including polyurethane foam filling. We stock a range of densities to meet your insulation, buoyancy and structural requirements.

Rotational molding foam filling is a secondary process that involves injecting a polyurethane foam into the hollow cavity of a rotomolded part. Rotational molding foam filling is used in a wide range products such as ice coolers, buoys, refrigerator components, and reinforced structural components.

Roto Dynamics offers a range of services for your rotational molding needs including polyurethane foam filling. We stock a range of densities to meet your insulation, buoyancy and structural requirements.

Foam filling is a unique three step process. First, a double walled rotationally molded plastic product must have the appropriate vents installed to allow the air inside the part to be displaced. Second, the part is held in a specially made fixture which maintains the part’s form to prevent it from deforming when the rapidly expanding foam is injected into the part. Three the polyurethane foam is injected into the rotomolded part at a high pressure to ensure the part is fully filled.

Insulation

This type of Rotational molding is crucial in the performance of high end retail coolers and commercial food processing units as it provides products with insulating properties which allow the product to maintain low temperatures. The general rule of thumb is, the higher the density of the foam, the better the insulation value.

Applications such as the one shown below rely on the foam filling process to keep food and drink cool while being transported in warm environments.

Buoyancy

This type of rotational molding is used in the manufacturing of floats and buoys as it provides two key functional properties. One, a low density foam provides buoyancy properties which allow a float to remain above the waterline. Two, the foam fill acts a barrier preventing fluid from entering the product should it get punctured.

Rigidity

Rotational molding foam filling is also used in applications where structural rigidity is required. This can be prticularly useful for parts with large flat surface areas. In addition, in rotational molding large flat surfaces tend to warp unless there is a structural feature or foam fill is in place.

The image below shows a structural sleeve that was clamped around an extremely heavy device which was mounted to a gimbal. The structural colar prevented the device from freely rotating when being transported. This part was molded with a ¼” wall thickness and filled with a high density polyurethane foam fill to provide added strength.

Properties provided by foam filling:

• Low temperature insulation
• Buoyancy
• Rigidity
• Impact strength
• Cushioning

For more information about foam filling your product contact our sales team.
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