MasterFoam

High-Performance Chemical Foaming for Polymer Processing

Utilised across many sectors including automotive, construction, and packaging, MasterFoam™ leverages safe, endothermic chemical foaming to optimise injection moulding. By creating a precise, closed-cell internal structure without hazardous gases, it allows you to lightweight components while maintaining structural integrity.

Why Choose MasterFoam?

Material and cost savings:
MasterFoam works at low addition rates of just 0.5% to 1%. By expanding directly in the mould, it reduces overall polymer requirements, lowering your raw material costs.

Boost output with zero capital expenditure:
Integrate MasterFoam into your existing setup to reduce cycle times and increase your productivity, without adding shifts or new machinery.

Seamless compatibility:
Custom formulations with polymer-specific carrier systems ensure compatibility with a broad range of moulding polymers.

Reduced environmental impact:
Benefit from reduced energy demand and a lower carbon footprint.

Aesthetic advantages:
Foaming is typically masked in coloured components, although in clear applications MasterFoam has been used to deliver a bubble aesthetic. MasterFoam has also been proven to reduce sink marks, enhancing the quality and appearance of mouldings.

Extrusion grade:
We also offer MasterFoam-Ex, designed specifically for extrusion processes.

The benefits of MasterFoam

Production worker in Broadway's masterbatch production facility

Non-toxic, endothermic reaction

Safe, controlled and non-toxic – MasterFoam replaces the volatile and aggressive exothermic chemistry of the past. By using a modern endothermic reaction, it eliminates the risks of thermal runaway and hazardous gas release, providing a stable alternative to outdated chemical foaming methods.

Component lightweighting

By replacing a percentage of polymer with microscopic gas pockets, MasterFoam typically achieves weight reductions of 5% to 10% in moulded products. Unlike irreversible thin-walling, no costly, permanent tooling changes are needed. MasterFoam offers the flexibility to produce standard and foamed parts from the same tool, just by switching materials.

Material cost reductions

Using less polymer will save you money. Over a large production run, a material saving of up to 10% can offer big cost reductions. So the more MasterFoam you use, the more money you’ll save!

Enhanced productivity

MasterFoam boosts output without capital investment or extra shifts. Because less polymer is required to fill the mould, shot speeds increase and cooling times drop. These optimised cycles maximise productivity, cut energy costs, and lower your carbon footprint too. Our extrusion grade, MasterFoam-Ex has been known to double line speeds.

Reduction of sink marks

The foam expands as the thermoplastic cools in the mould, offsetting shrinkage and reducing sink marks.

Improved insulation properties

By creating a closed-cell structure, MasterFoam introduces microscopic air pockets that act as thermal barriers and dampen sound vibrations. This improves the thermal and acoustic insulation of mouldings.

Versatility & low addition rates

Polymer-specific carrier systems ensure MasterFoam performs across a wide range of plastics. Effective at low addition rates, it’s a commercially appealing solution for injection moulded applications. As a bespoke, made-to-order solution, manufactured at our UK facility, MasterFoam provides security of supply and custom-tailored performance to meet your specific application requirements. Additionally, MasterFoam–Ex can be utilised in extrusion.