In the modern era, where environmental conservation awareness is at an exceptionally high level, the entire industrial sector is facing new challenges. The automotive industry, in particular, is exposed to the optimization of processes such as component weight reduction, product recycling, improved energy efficiency, and more. Our company's strategy is to manufacture more robust products in a shorter period of time, with lower energy and material consumption. By using foam injection molding technology, we succeed in implementing some strategic solutions while striving to upgrade our existing technology. For testing the foam injection molding technology, we used a production tool for a headlight housing without any additional optimizations. The reason for choosing this specific product was its significant weight, various wall thicknesses, and the presence of numerous fixing elements that can cause deformation due to uneven cooling. The testing was conducted on an injection molding machine that was upgraded with MuCell® technology, where we varied the nitrogen concentration in the polymer mixture. We measured the weight of the product and performed dimensional measurements on all samples. The study showed that, with the help of MuCell® foam technology, it is possible to reduce the product weight on average by five percent while improving dimensional repeatability in critical areas of the product by fifty percent.
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