Microcellular injection moulding is capable of producing lightweight polymeric products. The present study analyses the influence of several representative injection moulding parameters on the foam’s morphology, apparent density and thermo-mechanical properties of PETG, poly(ethylene terephthalate-co-1,4-cyclohexylene-dimethylene terephthalate) specimens. A strong variation of the cell morphology along the melt flow direction has been found, as well as a dependence on the shot volume. The most homogeneous microcellular structure is achieved when low shot volume, intermediate injection speed and low mould temperature are employed. The skin–core structure of the injected parts, determined the thermo-mechanical features of the specimen, which are ruled by the skin layer.

Peer Reviewed