E.S.F is a moulding process akin to Injection Moulding which takes any thermoplastic polymer, and by introducing a gas into the melt, produces an extremely rigid part. As a result, the component can be a structural element of the component and can negate metal superstructures or chassis, thus reducing TAC and assembly time.

Although ESF has been around since 1970’s, few people are aware of the benefits and design latitude this process can give. The honeycomb structure, sandwiched between two solid skins produces a component of such rigidity that it can begin to compete with metal fabrication or casting. Consequently the designer can achieve the strength of metal, combined with the formability of plastic – complex curves can be introduced into structural components.