Fast.
Bring us a sketch on a napkin. Four weeks later you are holding foamed production parts — design, formulation, mold and process, all under one roof.
weeks
Concept to production in 4 weeks.
Who is Moxietec?
Based in Pennsylvania, Moxietec® develops foaming technology for injection-molded and extruded plastics. ISO 9001 registered.
A turnkey partner. From concept to a full production line — run at Moxietec or dropped into your plants. Or bring us your current part and tool.
The goal: lighter parts, less resin, faster processing — with strength maintained or improved.
Bring us a sketch on a napkin. We will take it to a production line.
A concept, a CAD file, or a part you already mold today — we pick it up wherever it is. Product design, formulation development, mold design and mold manufacturing all happen on one campus in Pennsylvania, USA. No hand-offs between vendors, and nothing subcontracted.
And if you want the line automated — machine, mold and automation cell together — we can build you that too.
See how that runs, concept to production →A track record in high-tech, value-added parts.
Thick-walled, stiffness-driven parts where the foamed core takes out material — and improves compression strength and dart-drop impact.
Energy absorption and a cosmetic surface delivered in a single molded part, replacing a multi-piece assembly. We help make the world's strongest contact sports equipment.
Weight removed from parts that move constantly, without giving up the stiffness the assembly depends on.
We do not just say fast. We mold it live, on ENGEL® machines.
In 2025 we ran joint demonstrations of foam injection molding on ENGEL® equipment at two shows — K Show in Düsseldorf and PT Expo. Moxietec brought the technology; ENGEL® brought the machine. Foamed parts came off the press in front of the crowd.
Next, we are taking it on the road to NPE — come see our technology run, and hear how it works.
Foaming, and why ours is different.
As the part is molded, a controlled cellular structure forms inside the wall. The skin stays solid and cosmetic. The core becomes a honeycomb of tiny closed cells.
You remove material from where it does the least work — so mass and material drop while stiffness stays where the part needs it.
Conventional foaming gives you large, irregular, connected voids — which is why it has a reputation for weakening parts. Moxietec's formulations produce small, uniform, closed cells. Same idea, different physics, opposite result.
The first question an engineer asks about a foamed core is whether it will hold a screw. The answer surprises people: pull-out strength goes up, not down. The cell walls give the thread thousands of edges to grip, where solid material offers one smooth face. Tested across fastener types as part of process development.
Early packages: large voids, thin walls between them, structure that varies across the section.
Tuned packages: small cells, consistent distribution — that fine, even cell wall is what carries load and impact energy at reduced density.
This is the work an evaluation does — your resin, your geometry, screened before anything trials at your plant.
The additive is where it starts. It is not where it ends.
Our PFA does the hard chemistry — nucleating a fine, even cell structure in resins that fight it. But no additive can tell you what temperature, pressure and injection speed your part needs. Those settings are intellectual property in their own right, developed part by part, and they are what turn a strong formulation into a part that performs.
It runs on standard injection molding equipment — no special press, and existing tooling can often be used as it is. When a new tool is being built, we design the mold for the process too, so nothing is left to chance.
See how that runs, concept to production →
The tool is designed for the foaming process from the first sketch — gating, venting, cooling and surface decided together.
Not a product off a shelf. The PFA is formulated for your resin, your wall thickness and your target density — and it is one element inside the formulation, not the whole thing.
Two customers on the same resin get two different formulations — each tuned to raise part performance and lower molding cost. That is the difference between buying an additive and being given a technology.
Temperature, pressure, injection speed — established part by part, documented, and repeatable on production equipment.
Why it matters to you.
Same part. Same drop.
On the left, a large molded panel in the customer's standard formulation. On the right, the same part foamed with Moxietec® PFA.
Lighter — and it holds up.
Every capability in-house. One team, one building.
Formulation, product design, mold design, mold manufacturing and a fully equipped test lab all sit on one campus. One-stop shop, one accountable partner, no hand-offs between vendors.
From a part concept to a running production line.
Most suppliers own one box in this diagram and hand you to someone else for the rest. We own all of them — and with ENGEL® we can deliver the machine and the line too.
A part, a target weight, a target stiffness. Or just a problem.
Geometry engineered for a foamed wall from the first sketch.
Formulation developed and validated in our lab.
Tool designed and cut on our own floor. Not sent out.
Settings proven on the machine, then locked in.
A validated tool and a repeatable cycle — on your floor or ours.
A sketch, a CAD file, or a part you already mold today — we pick up from there.
Formulation, design, tooling and process all sit with one accountable team — so when something needs to change, it changes.
We can develop the part. Or the entire production line that makes it.
Machine, mold, foaming formulation, process settings and the automation cell around it — specified, built, installed and validated as one package, with ENGEL®. Others assemble a line from equipment they buy in; the lightweighting technology inside ours is our own. You get a line already making good parts, not a pile of equipment and four suppliers to coordinate.
Bring us the part you most want to make lighter.
Send us the part. We will assess it against our foaming technology and come back with whether it is a fit, and what the weight and cycle-time reduction would be. If it is, we can take it from there — to trial, to tool, to production.