The effect of polymer additives on surface quality of microcellular injection molded parts

Microcellular injection molding is an emerging process for producing foamed plastic parts with complex geometries. It has many advantages including material, energy, and cost savings as well as greater design freedom and dimensional stability. In spite of these advantages, this technique has been limited to non-aesthetic applications by its propensity to create parts with swirling patterns on the surface, a common characteristic of all foamed parts produced. This paper describes a novel method for achieving microcellular injection molded parts free of surface defects. By controlling the amount of supercritical fluid (SCF) and adding the proper type of polymer additives into the polymer, the onset and rate of cell nucleation were properly controlled so that swirl-free microcellular injection molded parts could be successfully molded. This paper presents the theoretical background and experimental results that demonstrate the effect of polymer additives on the surface quality of microcellular injection molded parts.