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Trexel, Inc.
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MuCell® Molding Technology
The most significant plastic processing
innovation in the last 20 years

The MuCell® microcellular foam injection molding process for thermoplastics materials provides unique design flexibility and cost savings opportunities not found in conventional injection molding. The MuCell process allows for plastic part design with material wall thickness optimized for functionality and not for the injection molding process. The combination of density reduction and design for functionality often results in material and weight savings of more than 20%.

By replacing the pack & hold phase with cell growth, lower stress parts are produced which have enhanced dimensional stability and substantially reduce warpage. Cell growth also results in the elimination of sink marks.

Unlike chemical foaming agents, the physical MuCell® process has no temperature limitation and does not leave any chemical residue in the polymer; making consumer products perfectly

suitable for recycling within the original polymer classification and allowing re-grind material to reenter the process flow.

The numerous cost and processing advantages have led to rapid global deployment of the MuCell® process primarily in automotive, consumer electronics, medical device, packaging and consumer goods applications.

Reduced Costs

Reduced resin consumption
Faster molding cycle time
Increased yields
Smaller molding machine
Use of lower cost filled polyolefin materials

Design Freedom

Thin to thick wall flow
1:1 wall thickness rib structure
Material where needed for function versus flow
Improved dimensional stability
Less warpage


Reduced petroleum based material consumption
Reduced molding machine energy consumption
Ability to re-grind / re-use molded parts
Reduced carbon footprint versus solid molding

Faster to Market

Fewer tooling iterations
Predictable molded part geometry
Ability to mold large partgle piece

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