Cooper Plastics Unveils Dual Structural Foam & Web Technology, Transforming Injection Molding in 2026

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Cooper Plastics, a plastics manufacturer based in Whiting, Indiana, has expanded its structural foam injection molding and structural web molding capabilities. The company's new processes allow for the production of large, complex plastic components with excellent strength-to-weight ratios, reduced material usage, and improved surface finish compared to traditional molding methods.

Why it matters

Cooper Plastics' dual structural foam and web molding technologies provide OEM customers across multiple industries with more design flexibility and performance-driven solutions from a single manufacturing partner. This can help drive innovation and cost savings in the production of large, lightweight plastic parts.

The details

Structural foam injection molding combines thermoplastic resin with a blowing agent to create parts with a solid outer skin and a lightweight foamed core. Structural web molding produces solid parts with internal hollow channels formed using low-pressure nitrogen, enabling 15-30% weight reduction compared to solid molded parts, improved surface finish, and elimination of sink marks in thick sections. Cooper Plastics' new 500-ton press supports ultra-large part production up to 120 pounds, primarily using HDPE, PP, and ABS materials.

• Cooper Plastics unveiled its new dual structural foam and web molding capabilities on February 23, 2026.

What they’re saying

What’s next

Cooper Plastics plans to showcase its new dual structural foam and web molding capabilities at an industry trade show in March 2026.