MuCell Microcellular

TM

Injection Molding
Processing Technology
MuCell Molding Technology TM

CYCLE TIME REDUCTION WEIGHT REDUCTION CLAMP TONNAGE REDUCTION

New opportunities for injection molders originate from a breakthrough molding technology, offering tremendous capabilities
never before seen with other molding processes. MuCellTM opens new markets for innovative product design, optimized
processing and reduced part costs. Products manufactured using MuCell technology are being developed and marketed in
a variety of industries worldwide, including automotive, medical devices, consumer goods, electronics, food services and
industrial and consumer structural parts.

Molders can gain a competitive advantage with the MuCell process by utilizing its processing benefits, e.g. endothermic
reaction, lower viscosity and lower melt and mold temperature. These benefits typically result in significant reductions in cycle
time, material consumption, injection pressure and clamp tonnage. This microcellular foam process is unique because it can
be applied to thin-wall parts and to materials that cannot be foamed successfully with any other foaming technologies. In
summary, competitive advantages can be achieved not only in existing markets, but also in new markets.

Injection molding applications of the MuCell molding

technology have produced the following results:

Up to 60% reduction in material viscosity due to the introduction

of the supercritical fluid

Significant reductions in processing temperatures (as much as

78 C, 140 F), resulting from lower viscosity

30-50% reduction in hydraulic injection pressure

Reductions in cycle time due to the elimination of hold pressure POLYOLEFIN TUBS:
and time • THIN-WALL APPLICATION OF 40 MFI POLYOLEFIN MATERIAL
• WALL THICKNESS - 0.5 MM (0.020”)
• ELIMINATION OF HOLD AND COOLING TIME
Controlled weight savings • FLOW RATIO = 280:1
• 10% MATERIAL REDUCTION

30-80% reduction in clamp tonnage

Elimination of sink marks

The innovative MuCell microcellular foam process, which was developed at the Massachusetts Institute of Technology
(MIT) and Trexel, is covered by patents and patents pending in Asia, Europe and North America. The MuCell molding
technology is available as an option on selected new injection molding and structural foam molding machines. All
MuCell-capable injection molding machines and structural foam machines are also capable of conventional,
non-foaming operation.
 MEDICAL HANDLES:
• PC AND POLYSULFONE
• UP TO 30% WEIGHT REDUCTION
• 50% CYCLE TIME REDUCTION
• CLAMP TONNAGE REDUCTION FROM
120-TONS TO 15-TONS
• ABILITY TO MOLD DIFFICULT TO
FLOW MATERIALS

AIR INTAKE MANIFOLD GASKET:

• PA 6/6 - 33% GLASS-FILLED
• 66% COOLING REDUCTION

MuCell TM • CONTROLLED WEIGHT REDUCTIONS OF 5, 10, 15, 20%

• CLAMP TONNAGE REDUCTION FROM 150-TONS TO 40-TONS

Technology Applications
The MuCellTM process technology is being applied to a broad range of
injection molded thermoplastic materials and applications. Molders are
currently taking advantage of the unique process benefits that MuCell
provides. The applications that have been selected take advantage of the
controlled weight savings and significant reductions in cycle time. Many
products have been converted from larger machines to smaller MuCell
equipped machines utilizing the drastic reductions in clamp tonnage. Most
notably, the process is being applied in applications never before thought
possible with other conventional technologies.

FUSE BOX: Filled and unfilled materials such as nylon (PA), polycarbonate (PC),
• 22% MICA-FILLED
POLYPROPYLENE COPOLYMER
polypropylene (PP), polycarbonate/acrylonitrile butadiene styrene (PC/ABS),
• 17-20% WEIGHT REDUCTION IN THREE DIMENSIONAL polystyrene (PS), acetal (POM), polyethylene (PE), high-temperature
PRODUCTS WITH VARIED WALL THICKNESS DOWN TO 0.5MM (0.0020”)
• LIVING HINGE sulfones, and TPE’s, (e.g. Santoprene and Kraton) have been molded.
• ELIMINATION OF SINK MARKS

HVAC DOOR:
• PA 6/6 - 40% GLASS-FILLED
• 30% CYCLE TIME REDUCTION
• EXCELLENT DIMENSIONAL STABILITY
• CLAMP TONNAGE REDUCTION
FROM 200-TONS TO 30-TONS
AIR DISTRIBUTION HOUSING:
• FILLED POLYPROPYLENE
• LARGE COMPLEX MOLD
• 10% WEIGHT REDUCTION
• 20% CYCLE TIME REDUCTION
FAN MOTOR HOUSING:
• 25% TALC-FILLED POLYPROPYLENE COPOLYMER
• 15% WEIGHT REDUCTION IN THIN COMPLEX SHAPES
• ELIMINATION OF SINK MARKS
• ELIMINATION OF HOLD PRESSURE AND TIME

ACETAL HIGH WEAR AUTOMOTIVE TRIM:

COMPONENTS: • PP OR PC/ABS
• WEIGHT REDUCTIONS UP TO 40% • IN-MOLD DECORATION
• 20% CYCLE TIME REDUCTION • 28% INJECTION PRESSURE REDUCTION
• CLAMP TONNAGE REDUCTION FROM 150-TONS TO 40-TONS • MELT PROCESS TEMPERATURE REDUCTION
• ABILITY TO MOLD DIFFICULT TO FLOW MATERIALS • IMPROVED FABRIC/LAMINATION QUALITY
• ELIMINATION OF SINK MARKS
MuCell Microcellular Process TM

Four Technology Steps:

1. GAS DISSOLUTION
A supercritical fluid (SCF) of an atmospheric gas (CO2 and N2) is injected into the polymer through injectors installed
in the barrel to form a single-phase solution. The SCF delivery system, screw and injectors are specifically
designed to facilitate the rapid dissolution of the SCF in the polymer.

2. NUCLEATION
A large number of nucleation sites (orders of magnitude more than with conventional foaming processes) are
formed throughout the polymer during the molding process. A substantial and rapid pressure drop is necessary to
create the large number of uniform sites.

3. CELL GROWTH
Cell growth is controlled by processing conditions. Precise control of pressure and temperature is achieved through
specifically-designed machine controlled hardware and software.

4. SHAPING
After injection into the mold, part shape is controlled by the mold design. Although mold modifications are not
required, in some cases modifications will optimize the benefits of MuCellTM.

Adapting the MuCell process injection molding requires the following changes
or additions:
A SCF metering system with sufficient capacity to deliver the SCF blowing agent to the screw at the rate and
pressure required for the MuCell process. (Trexel’s Equipment Division supplies properly-configured pump
systems for SCF delivery and other proprietary components to licensees)

A Trexel-designed screw for creating a single-phase solution of the SCF blowing agent. (The screw design
allows for both solid and MuCell materials to be processed)

Minor modifications to software, system hardware and hydraulics to create and maintain the uniformity of the
single-phase solution throughout the injection molding cycle

MuCell Machine Requirements Equipment Modifications

MuCell Screw and Barrel
Melt pressure Barrel modifications
transducers
MuCell SCF injector
Air-cooled heater bands MuCell MuCell SCF metering system
screw and barrel Minor software and hydraulic changes
Equipment can operate in both solid
and MuCell modes.

Shut-off SCF
nozzle
ports

Fig 1.1
49” x 24” x 61.25”
Minor software and hydraulic changes SCF gas unit supplied by Trexel (See Fig 1.1) (125cm x 61cm x 156cm)
MuCell Technology TM

Cost Savings
Areas of Potential Savings

Where do CYCLE TIME COLORANT REDUCTION

potential cost ENERGY CONSUMPTION

savings
come from? REDUCTION IN
TOOLING COSTS

REDUCTION IN INITIAL
INVESTMENT
MATERIAL REDUCTION
ELIMINATION OF CBA COSTS

Savings and Paybacks

400,000 1.4

350,000 1.2

300,000
1
Payback (Years)
Savings/ Year

250,000
0.8 Material Savings
200,000 Cycle Time Savings
0.6 Payback
150,000
View right axis for Payback
0.4
100,000

50,000 0.2

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Application
(Material)
 Implementing MuCell TM

Technology
STEP 1: CONTACT A LICENSED OEM INJECTION MOLDING EQUIPMENT SUPPLIER AND
TREXEL FOR HARDWARE AND LICENSE QUOTATIONS.

For a list of licensed OEM machine suppliers, please refer to our website or contact us directly.

STEP 2: OBTAIN A MUCELL END USER LICENSE AGREEMENT FROM TREXEL, GRANTING
USER RIGHTS TO MAKE, USE AND SELL MICROCELLULAR FOAM PRODUCTS.
Trexel provides the MuCell license to end users on a machine-by-machine basis
The machine license is paid annually for seven years, after which it is fully paid and irrevocable
The annual license fee is determined by:
Machine size (measured in clamp tonnage)
Resin type (either restricted: commodity type resins such as PP, PE, and PS, or
unrestricted: all resin types)

MuCell is a trademark of Trexel, Inc.