Expandable polystyrene (EPS) has been used in numerous and varied applications. Its products are commonly made via the steam injection moulding process. This paper discusses a new process approach using ground recycled EPS mixed with powder adhesive to produce the specimens. Adopting the design of experiment approach, the amount of recycled EPS was found to be the most significant controlling parameter for this process. The optimal process conditions and empirical relationships for good bead fusion were also established and the specimens derived were found to be good and comparable with those of steam injected moulded ones. Common causes of failures were also identified.
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