MuCell® Microcellular Foam Molding

Totally committed to providing the highest quality and service, Genesis Plastics & Engineering, LLC is applying the MuCell® technology to offer its customers a unique product. Focusing on the MuCell® technology as a process to solve existing problems provides a competitive edge.

The MuCell® Process can be integrated into most molding applications to significantly increase productivity while simultaneously decreasing operating costs. The MuCell® technology:

• decreases material usage
• increases dimensional stability
• improves process consistency
• reduces cycle times
• reduces injection pressures
• reduces clamp tonnage
• reduces warpage
• improves flatness
• eliminates sink marks

The MuCell® process converts either nitrogen or carbon dioxide into a super critical fluid (SCF), which is then combined with melted plastic before it is injected into mold. The SCF acts as a temporary polymer plasticizer, which significantly reduces the viscosity of the resin. This allows the temperature of the barrel and the mold to be decreased therefore reducing cooling time. The plasticized polymer is injected using lower injection pressures requiring less clamp tonnage. This allows parts to be molded in lower tonnage machines, creating lower cycle, lower molded in stress and increased dimensional stability. During injection the SCF creates a microcellular structure in the polymer. The microcellular growth compensates for processing complications such as sink marks and part warpage without altering the chemical composition of the polymer. Lower clamp tonnages allow for higher cavitation molds to be used within the same machine. In some applications lower percentages of SCF allow for improved surface finishes on lightly textured parts. This allows the molder to take advantage of the benefits of the MuCell process without losing structural properties of the polymer.