Microcellular plastics (MCP) refer to any plastic with tiny bubbles of less than about 50 microns. It is made by subjecting polymers with a large amount of dissolved gas to a thermodynamic instability so as to nucleate a large number of cells instantaneously. MCP has been extruded and injection molded to make various industrial products. The fundamental theory for design of MCP and the processing methods are reviewed. It also discusses the design of equipment, including the die or mold, for MCP processing. The performance of MCP and the advantages of using MCP are presented. Some of industrial applications are also highlighted.
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Nam P. Suh (2003) studied this question.