TREXEL

TREXEL

US-based TREXEL is the developer of the microcellular foam injection molding technology MuCell and its sole authorized provider worldwide.

What MuCell is

The essence of the process is this: a supercritical fluid (nitrogen or carbon dioxide) is injected into the melt. When the pressure drops inside the mold, this fluid forms millions of microcells. The result is a part with a porous interior but a smooth surface.

The difference from chemical blowing agents is that it leaves no chemical residue — the part remains recyclable.

What it delivers

• Up to 20% weight reduction — a direct saving in material cost
• Fewer sink marks and less warpage — because the internal pressure compensates for shrinkage, the surface stays smooth even in thick sections
• Lower clamping force — because the in-mold pressure drops, the same part can be produced on a machine with a smaller tonnage
• Shorter cycle time — the holding phase is shortened considerably

The physical cause of sink marks and the classic solutions are explained on the sink marks page; MuCell approaches this problem from a different angle.

System components

A complete installation consists of two main parts: the [NC series booster](/en/products/trexel-nc-250-booster), which brings the gas to the supercritical state, and the [T-Series Satellite](/en/products/trexel-t-series-satellite) unit, which does the dosing beside the machine. Adaptations are also required on the screw and control side of the injection molding machine.

Who it suits

It can be applied to almost all thermoplastics except LCP; results are best with filled materials. It is considered in automotive, household appliance and technical part production, especially for thick-walled parts with sink mark problems.

In Turkey, the real obstacle to MuCell is not price but awareness; our article on MuCell foam injection molding, which explains the technology in Turkish, and our product pages were prepared to fill this gap.