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Structural Foam Molding Services | Lightweight Large Parts

Transform your large-scale manufacturing with EVOK's advanced structural foam molding services. Our specialized process delivers exceptional strength-to-weight ratios, making it ideal for producing oversized components that traditional injection molding can't handle. From automotive panels to industrial equipment housings, we engineer lightweight, durable parts with superior dimensional stability and reduced material costs—all while maintaining the precision and quality you demand.

Large structural foam molded component with cellular core structure

Our Structural Foam Molding Services

Comprehensive solutions for large-format plastic components, from initial design consultation to high-volume production of lightweight, structural parts.

Parts Design & Engineering

Expert structural foam part design optimized for strength, weight reduction, and moldability. Our engineers analyze wall thickness, rib placement, and cellular core structures to maximize performance while minimizing material usage and cycle time for large components.

Prototype Development

Rapid prototype services for structural foam parts to validate design, structural integrity, and surface finish before production tooling investment. We help you see and test your large-format components early in the development process.

Material Selection

Strategic material selection for structural foam applications, balancing density, strength, chemical resistance, and cost. Our expertise spans engineered resins specifically formulated for foam molding processes to achieve optimal cellular structures.

Mold Design & Manufacturing

Custom mold design and fabrication for structural foam molding, incorporating proper venting, gas injection systems, and cooling optimization. We build tooling solutions that deliver consistent cellular structure and minimal sink marks on large parts.

Production & Quality Control

High-volume structural foam molding production with rigorous process monitoring and inspection protocols. Our quality systems ensure dimensional accuracy, consistent density, and structural performance across every production run of your large-format components.

Analytical Testing

Comprehensive analytical testing including structural analysis, density measurements, and mold flow simulation. Our problem-solving approach uses advanced tools to optimize foam cell structure, minimize defects, and validate part performance.

Advanced Manufacturing

Engineered for Strength, Optimized for Weight

Structural foam molding represents the pinnacle of large-part manufacturing technology. Unlike standard injection molding, our process creates parts with a solid outer skin and a cellular foam core—delivering exceptional rigidity at a fraction of the weight. This makes it ideal for oversized components up to several feet in length that would be impossible or cost-prohibitive with conventional methods. With 25 years of injection molding expertise, EVOK combines proprietary techniques with deep material science knowledge to engineer structural foam parts that exceed performance expectations while reducing your total production costs.

Cross-section view of structural foam molded part showing cellular core
Proven Excellence

Trusted By Industry Leaders

Over 25 years, we've delivered structural foam solutions for major manufacturers across automotive, powersports, and industrial sectors.

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool
The EVOK Difference

Why Choose EVOK for Structural Foam Molding?

We combine decades of specialized expertise with innovative problem-solving to deliver large-format parts that meet your exact specifications.

25+ Years Expertise

Over two decades specializing in advanced injection molding technologies, including structural foam processes for complex, large-format components across diverse industries.

Engineering-First Approach

Our Six Sigma-certified team conducts thorough design reviews, mold flow analysis, and tolerance studies to optimize every structural foam part for manufacturability, performance, and cost efficiency from day one.

Complete Development Pipeline

From concept feasibility and rapid prototyping through production tooling and high-volume manufacturing—we guide your large-part project through every stage with transparent communication and collaborative problem-solving.

Transparent Pricing

We're upfront about costs at every stage, itemizing tooling, material, and production expenses so you can make informed decisions. Our goal is optimized part pricing without compromising quality or performance.

Meet The EVOK Team

Experienced engineers and designers passionate about solving complex molding challenges.

Paul Dathe, Founder and Chief Engineer at EVOK Polymers

Paul Dathe

Founder

Paul Dathe founded Evōk Polymers with a singular mission: delivering the highest quality injection molded components at the lowest possible price through proprietary technology and deep industry expertise. With over 25 years specializing in engineering, product design, and solving complex injection molding challenges, Paul brings unparalleled depth to every project. He holds four U.S. utility patents and earned Six Sigma black belt certification, applying rigorous process optimization to mold design engineering. Prior to founding EVOK, Paul led new product development at Caliber Products, launching 13 products while growing sales 540% and expanding from 25 to 144 customers with 100% retention. His responsibilities spanned tooling design, functional assessments, 3D modeling, prototype fabrication, tolerance analysis, and mold flow studies. Earlier, as Senior Mechanical Engineer at Entegris, Paul managed a $40 million product line of ultra-clean liquid delivery systems for semiconductor applications. He began his career at Rollerblade in design and prototyping before serving in senior engineering roles at General Mills and Boston Scientific. Paul earned his Bachelor of Science in Mechanical Design from Bemidji State University with emphasis in rapid prototyping and 3D computer modeling. He's an active member of Allied Executives Business Leadership Peer group and the Institute of Packaging Professionals.

Jason Weber, Industrial Designer at EVOK Polymers

Jason Weber

Industrial Designer

Jason is a seasoned industrial designer with a passion for creating innovative and functional injection molded products. His design philosophy is deeply influenced by his life within a multi-generational household with his wife, two sons, and mother, which nurtures innate empathy and keen observation of human behavior—qualities that translate directly into user-centered design excellence. Jason brings creative vision to EVOK's engineering projects, balancing aesthetic refinement with manufacturing practicality. His ability to understand how people interact with products ensures that every component he designs not only meets technical specifications but also delivers intuitive functionality and ergonomic comfort. Jason's multidisciplinary approach bridges the gap between pure engineering and real-world application, helping clients create products that resonate with end users. Outside the studio, Jason finds inspiration through cooking, gaming, and relaxation, activities that fuel his creative process and problem-solving abilities.

Shawn Monitor, Sr. Industrial Designer at EVOK Polymers

Shawn Monitor

Sr. Industrial Designer

Shawn Monitor has been an instrumental creative force on some of the most advanced injection molded seating and component projects of the last two decades. His particular expertise lies in graphically and physically communicating evolving design concepts and intricate part features through complex mechanical and visual prototypes built in diverse materials. Shawn creates photorealistic renderings using Otoy OctaneRender® and develops professional layouts, diagrams, and logos with Adobe Creative Cloud, providing clients with clear visualization of engineering concepts before tooling commitment. His deep involvement in pre-molding design reviews has significantly reduced risk on numerous large-scale projects by identifying and resolving potential manufacturing issues early in the development cycle. Shawn excels at finding mechanical molded part solutions that can be prototyped and validated prior to expensive production tooling, saving clients time and money while ensuring design intent is maintained. He holds several patents reflecting his innovative approach to injection mold component design. Beyond his professional achievements, Shawn practices photography and enjoys the vibrant Twin Cities live music scene, interests that sharpen his visual communication skills and creative thinking.

Daniel D. Hoyt, Ph.D., Business Development Manager at EVOK Polymers

Daniel D. Hoyt, Ph.D.

Business Development Manager

Daniel brings exceptional expertise in system and process design engineering, coupled with strategic partnership cultivation that sets EVOK apart in the injection molding industry. His passion for innovation and collaboration drives initiatives that challenge traditional norms in part design, prototyping, tooling, and injection mold manufacturing. Daniel's vision extends beyond disruption—he's building a community centered on continuous improvement, mutual benefit, and genuine partnership that empowers small and mid-sized businesses to compete at the highest levels. His leadership focuses on creating Lean Partnership-Based Organizations that optimize engineering processes and deliver sustainable growth. Daniel's proficiency as a facilitator, public speaker, teacher, and coach, combined with exceptional team-building and mentorship abilities, accelerates EVOK's mission to transform industry standards. Under his guidance, EVOK establishes new benchmarks for collaborative engineering success, ensuring clients receive not just technical expertise but strategic insights that drive their competitive advantage in demanding markets.

Natalie Weber, Operations Officer at Evok Polymers

Natalie Weber

Operations Officer – LIV

Natalie is a dedicated apprentice in product design and management who embodies the harmonious blend of creativity and sustainability in injection mold engineering. Possessing innate curiosity and a discerning eye for innovation, she tirelessly explores where design converges with environmental consciousness—bringing fresh perspectives to material selection and dematerialization strategies. Immersed in intangible design principles since childhood, Natalie grasps the profound impact injection molded products can have on the planet, driving her commitment to infusing eco-consciousness into every project facet. Her education in sustainability, combined with hands-on mentorship from seasoned professionals, accelerates her mastery of product design intricacies. Natalie investigates diverse materials, manufacturing techniques, and emerging technologies, always evaluating their ecological footprint and lifecycle implications. Her journey extends beyond creating aesthetically pleasing components—she's shaping a future where injection mold design engineering seamlessly integrates sustainability principles, leaving a positive legacy for generations while meeting demanding performance specifications.

Julie Young, Accounting and Finance Manager at Evok Polymers

Julie Young

Accounting and Finance Manager

Julie Young has been an integral part of Evok since its inception, bringing meticulous attention to detail and thorough financial expertise to the organization. As an experienced accounting professional, she excels in organizing and categorizing transactions, reconciling accounts, and producing clear, concise financial reports that enable informed business decisions. Julie's proficiency in accounting software ensures streamlined processes and timely delivery of financial information, maintaining compliance with all regulatory requirements. Her dedication to professionalism and confidentiality provides the financial backbone that supports Evok's operations and growth. Beyond standard bookkeeping, Julie plays a critical role in vendor relationship management, ensuring all partners are paid promptly and maintaining the trust-based environment that is central to Evok's values. Her reliable financial services support both the team's effectiveness and customer satisfaction by ensuring resources are properly allocated to deliver exceptional injection molding solutions.

Frequently Asked Questions

What is structural foam injection molding?

Structural foam injection molding is an advanced manufacturing process that creates large plastic parts with a solid outer skin and a cellular foam core. A chemical blowing agent is mixed with molten plastic resin, which expands during injection to form millions of tiny gas bubbles throughout the part's interior. This creates a lightweight, rigid structure ideal for oversized components that would be impractical or too heavy with standard injection molding.

How strong is structural foam?

What is structural foam used for?

How thick is structural foam?

Can foam be injection molded?

What is the injection foam method?

What is the process of foam molding?

What materials work best for structural foam molding?

Have Questions About Structural Foam for Your Project?

Our engineering team is ready to discuss how structural foam molding can solve your large-part manufacturing challenges.

Certified Excellence

Awards and Recognition

Six Sigma Black Belt Certification

Six Sigma Certified

Black belt process optimization expertise

Manufacturing Excellence Award Icon

25+ Years Manufacturing Excellence

Over two decades delivering quality molded components

Industry Association Membership Icon

Industry Leadership Recognition

Allied Executives & Institute of Packaging Professionals

Ready to Start Your Structural Foam Project?

Share your project details and our engineering team will contact you within 24 hours to discuss design requirements, material options, and cost estimates for your large-format components.

Contact Us Today

For immediate assistance, feel free to give us a direct call at +1 612-991-2001.