Structural Foam Injection Molding Design Guide

Download this handy design guide that covers the structural foam molding process, its uses and many benefits.

Designers and engineers are often not as familiar with structural foam molding as they are with standard plastic injection molding.

Miles Products created this guide to highlight the many opportunities structural foam molding offers manufacturers.

Our Structural Foam Molding Design Guide Covers:

Specifications and tips for reference while planning to work with structural foam molding.

Wall Thickness

Material Flow

Transition Sections

Radii and Fillets


Draft Angles

Bosses and Ribs

Plus more design tips

Also in the Guide Are Details On


The guide explains various structural foam molding processes, techniques and its unique advantages.

Multi-Nozzle Technology. The introduction of multiple nozzles allows for the production of larger and more complex parts, up to 72″x72″x24: in size. This technique is also used to mold multiple parts simultaneously.


Gas-assisted molding uses pressurized gas to aid and improve the plastic material flow. The guide goes through the process and benefits.

Also known as structural web, gas-assist molding gives designers more flexibility during production of large plastic parts. The process allows the molding of thinner walls and the use of features such as taller ribs and bosses.


The large durable parts are particularly well suited for certain industries, products and demanding applications. Some of these industries and types of parts are listed.

Assembly and secondary operations are highlighted. These include fasteners and inserts commonly used, typical snap-fit joints and specs, painting and finishing techniques.

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