COMMODITY STRUCTURAL FOAM MATERIALS FOR AUTOMOTIVE APPLICATION Structural foam plastic materials are increasingly being used in engineering functions as well as in areas where styling and aesthetics are important. Recent developments in plastic part designs and in processing research point toward significantly increasing uses of structural foam for automotive and truck applications. Plastic structural foam parts are now being molded that are as large as 12 feet in the longest dimension. Existing molding equipment will allow part weights as great as 100 pounds to be processed. It is technically feasible to mold passenger compartment-sized parts with the present state of the art. Physical property data for structural foams are presented to assist designers and engineers in their work.