XtraLite™

XtraLite™ provides a quantum leap in microcellular injection molding technology by eliminating the rough surfaces and other irregularities common to existing microcellular foaming processes. The XtraLite process can be easily added to existing injection molding machines.

Intellimold with XtraLite™ is a microcellular injection molding process that can significantly reduce part weight while also yielding components with a Class-A finish. The XtraLite process works in conjunction with the Intellimold technology.

Intellimold with XtraLite also improves flow length, pushes out sinks and eliminates sinks in parts with unconventional cross-sectional areas, and provides a consistent microcellular structure.

XtraLite employs conventional chemical blowing agents rather than the supercritical fluids used in machines outfitted by a leading microcellular foaming supplier. The result is a process that has easier process control and setup, requires no additional capital investment, requires no special screws, and has no high pressure gases/cryogenic liquids and couplings that can pose safety issues.

How does Intellimold with XtraLite work? In simplistic terms, it is not much different than opening a can of cola. Once the pressure is released by opening the can, the trapped air bubbles inside the cola rise to the surface. Within the injection molding process, Intellimold keeps the air bubbles created by blowing agents under pressure and away from the cavity surface. Intellimold is able to accomplish this because it utilizes a pressurized mold cavity and controls the internal melt pressure within the cavity.

The ability to mold parts with a Class A finish has been a major obstacle to greater proliferation of microcellular foaming. Since XtraLite forms a skin on the part surface so no gas bubbles appear, it can be used on parts requiring cosmetic or class-A surfaces. As the mold cavity fills, Intellimold with XtraLite controls the internal melt pressure and ensures that the plastic, not microcell or gas bubbles from the blowing agent, reaches the part surface. The result is a lighter part with a smooth, high-quality finish.

The XtraLite process provides a consistent microcellular structure.

There are no limitations on part or injection machine size. The process achieves the same tight tolerances as the Intellimold system and is not limited by wall thickness or part geometry. In addition, parts in multi-cavity and family molds can benefit from XtraLite. As with Intellimold, the XtraLite feature “pushes out” sink marks.

To demonstrate the benefits of the XtraLite system, the same 400-gram automotive body cladding was molded using conventional injection molding, a competitive microcellular foaming process, and IntelliMold with XtraLite. The part using a competing microcellular foaming process achieved a 12% weight reduction compared to conventional injection molding, but its surface was not smooth or Class-A quality. The same part molded using XtraLite yielded a 15% weight reduction and had a smooth, paintable Class-A surface. Greater weight reductions can be achieved with parts that have a thicker cross section.