Hybrid process molds lighter high-performance parts

Davis-Standard blow molding customer, Pinnacle Plastic Products, has embarked on molded parts innovation by successfully using a hybrid process called Foamcore® to mold parts with a solid skin and foam interior as a lightweight, economic, high-performance alternative to PU foams, and carbon fiber parts.

The company is already producing parts for commercial parking stop/wheel chock applications with several others on the horizon. Pinnacle was recognized by SPE for “Best Industrial Part” in the fall of 2014, and at NPE 2015, earning the award for “Most Innovative Part” in the Sustaining Life Category.  

Foamcore® is unique in that it combines extrusion blow molding with the steam chest molding process to produce a skin on a solid foamed part, according to Mike Hagen, Pinnacle Plastic Products’ President and co-owner. The process creates numerous advantages including reduced part weight with excellent strength properties, thermal and acoustic benefits, moisture resistance and the advantage of maintaining versatility in the blow molding process.

The parking stop is the perfect example produced using this process as the finished product is durable, water-resistant, and light weight at only 7 pounds. It can also be custom colored, shipped, and installed at a fraction of the cost when compared to heavy concrete parking stops. Plus, it minimizes damage to low profile vehicles that park too close.

Mark Panaro, Product Manager of Davis-Standard Blow Molding Systems further said that Pinnacle Plastic Products has achieved an impressive outcome using Davis-Standard equipment with the development of new processes that impact the marketplace in such a positive way.  

Pinnacle Plastic Products has a strategic and exclusive agreement with Direct Link Solutions (DLS), owner of the intellectual property rights for Foamcore in North America and the Western hemisphere. The opportunities for new applications are vast, especially for automotive parts where energy absorption and weight reduction is essential to achieve better fuel economy.

Foamcore parts are an average of 40 percent lighter than comparable parts. Automotive parts being evaluated for Foamcore include bumper systems, step assist rails, rear seat backs, load floors and covers. Examples of non-automotive parts include safety barriers, hospital furniture, showers and tub supports, spa components and railroad ties. Pinnacle is using Davis-Standard accumulator head blow molding machines to support this ingenuity.

The environmental benefits of Foamcore are also noted. Depending on application, Foamcore is almost always recyclable. In many cases, it is 100 percent recyclable. Old or damaged parts can be ground up and put back into the process.