In this project, the University of Kassel investigated the local core-back technique to achieve higher expansion ratios for creating less dense parts and to achieve a homogeneous foam structure in foam injection moulding. Different from the standard core-back, the cell growth and density reduction were mainly restricted to the locally expanded areas with the local core-back technique. Boundary conditions and process parameter settings greatly influenced the formation of the foam structure in both expanded and non-expanded areas. With Moldex3D Foam Injection Molding Analysis, University of Kassel was able to obtain a better understanding of the structure formation during the process and further optimised the process conditions.