Better Products by Design
FOAM FILLING SOLUTIONS FOR ROTOMOLDED PARTS
FOAM FILLING SOUTIONS
At EnviCor, we bring precision, innovation, and consistency to every stage of the rotational molding process, including advanced foam filling capabilities. Foam filling is a specialized manufacturing technique where rotomolded parts are filled with a foaming material to enhance certain properties, such as sound and vibration damping, thermal insulation, buoyancy, or strength and rigidity.
With our formidable experience as a specialized rotational molding manufacturer, EnviCor has the equipment and expertise to deliver consistent results on even the most complex parts through in-process polyethylene foam or secondary-process polyurethane foam.
WHAT IS FOAM FILLING FOR ROTOMOLDED PARTS?
In-process foam filling refers to the addition of a powdered polyethylene substance that is added to the mold and released during the heating process. The heat causes the powder to melt and expand as a foam, filling the mold. Parts filled this way offer enhanced performance in a variety of applications.
In secondary-process polyurethane foam injection, a liquified polyurethane foam is injected into a finished or partially finished roto-molded part. Once inside, the foam expands to fill the internal cavity, hardening to create a lightweight yet rigid core. This process is ideal for applications that require enhanced rigidity, impact resistance, or thermal insulation without significantly increasing part weight.
Benefits of Foam Filling in Rotational Molding
EnviCor’s foam filling solutions provide:
Enhanced Strength & Impact Resistance – The foam core increases load-bearing capacity and resists deformation under stress.
Improved Insulation – Perfect for products that must maintain temperatures, such as coolers, refrigerated enclosures, or insulated containers.
Weight Reduction – Foam filling achieves strength without adding unnecessary mass, making products easier to handle and transport.
Noise Reduction – In certain applications, the foam helps dampen vibration and sound.
Bouyancy – Foam filling is quite buoyant, making it useful for nautical applications
ENVICOR FOAM FILLING CAPABILITIES
EnviCor has invested in state-of-the-art foam injection systems to ensure precise mixing, expansion, and curing. Whether your part requires full-cavity foam filling or targeted reinforcement in specific areas, our process delivers consistent density and adhesion.
EnviCor can foam-fill parts of various sizes, shapes, and complexities, thanks to our extensive in-house tooling and broad rotational molding capabilities. We work closely with customers from initial design through final production to ensure optimal wall thickness, foam volume, and overall part performance.
Some Examples of Applications Requiring Foam Filling
Our foam filling services are widely used in countless applications across the industrial spectrum. Here are just a few examples:
Recreational Products – Kayaks, canoes, paddleboards
Food & Beverage – Insulated coolers, transport bins
Industrial – Tool cases, protective housings
Marine – Buoyancy aids, dock floats.
Agriculture – Insulated storage tanks, feeders
LOOK TO ENCIVOR FOR
FOAM FILLING EXPERTISE
When you need foam filling integrated seamlessly into your rotational molding project, EnviCor delivers the experience, technology, and quality assurance to make it happen. Our team works with you to ensure the appropriate material is used so the final product meets strength, insulation, buoyancy, and all other requirements.
Contact us today to discuss how EnviCor’s foam filling services can enhance your next product.