This cottage may look like child’s play from the outside, but it actually showcases difficult molded-in decorative features that stretch the capabilities of low-pressure structural foam molding. Take the roof, for example. Horizon Plastics, which won the competition’s consumer products and people’s choice awards, molds the front and rear roof components out of foamed polypropylene and polyethylene, using aluminum tooling. According to Brian Read, Horizon’s president, structural foam was a natural choice given the size and durability requirements for the roof components. But it also allowed the part designers to include a heavy molded-in texture that simulates the look of cedar shakes.
For more information on low-pressure structural foam, go to http://rbi.ims.ca/4927-532.