When it comes to product development, there are always a few surprises in the design stages that need to be addressed. For example, an electronic device may malfunction in extreme temperatures during testing, or a medical device may generate excessive noise that disrupts patients when they try to use it. We work with OEMs to help them resolve energy management challenges and other product issues by providing tailored molded polyurethane foam solutions.

The beauty of custom molded foam is that many options are available based on the project’s requirements. Polyurethane foam is a good material for various applications because of its heat resistance, sound control, and cushioning properties. Our POLYFORM® line of molded open cell polyurethane foams is an excellent example of the flexibility and effectiveness the Polymer Molded Products (PMP) division can achieve with molded foam.

This short guide will help you understand the advantages of using molded foam and the properties that will help determine the proper formulation. You will learn about our POLYFORM® polyurethane foams and examples of their use for critical energy management and impact mitigation functions. We will also walk you through how the process with our PMP division works to forge your own molded foam.

The Advantages of a Custom Molded Foam Solution

While both 3D molded and 2D cut foams can be used for energy management and cushioning, molded foam is custom designed to fit perfectly inside the product. Molded polyurethane foam can be formed by injecting liquid polyurethane into a mold, allowing for complex shapes, varying densities, and integrated features.

The initial manufacturing cost will likely be more than 2D cut foam, but it will also be less time-consuming and more cost-efficient in high-volume production. 3D molded foams don’t require hand-cut pieces and eliminate the need for fasteners, screws, and other parts to simplify the assembly process. They also tend to have a longer lifespan and far more design flexibility than die-cut foams.

Other general benefits of molded foam include improving the quality and performance of the product, reducing the amount of suppliers needed, and simplifying inventory management.

Factors that Determine the Right Molded Foam Formulation

One advantage of choosing a molded foam solution is the amount of customization available to meet the specific product requirements. Our molded foams can be molded into various shapes and sizes and engineered to have different surfaces. Formulations in our POLYFORM® solutions, for example, include self-skinning and non-skinning options for multiple applications.

Self-skinning foams have a tough outer layer for extra durability and sound barrier properties. They are often used in over-molding applications and are more suitable for harsh environments. Non-skinning foams are softer and more flexible for sound attenuation, sealing, and cushioning.

All of our POLYFORM® molded foam solutions are open cell foams. Open cell foams are relatively lightweight and spongy with some permeability. They offer excellent resilience, good thermal insulation, and flame resistance.

However, for some applications, a 2D cut foam piece for each component might be better, so die-cut foams can’t be completely ruled out. Examining all energy management and assembly requirements is essential to determine the right foam solution. Considerations for weighing foam solution options will likely include the following:

• The dimensions of the product
• The environments the product will be exposed to
• The improvements in energy management and other benefits sought
• The current assembly process and expected product volume

We will discuss our PMP molded foam process more below, but first, let’s take a closer look at our POLYFORM® product line and where they have been used to solve real-world challenges.

Mold Your Vision with POLYFORM® Molded Foams

The PMP division can discuss your needs to determine the right molded foam solution for your project. Our POLYFORM® line of molded foams has various formulations to tackle specific energy management and impact challenges.

• POLYFORM® High Density Molded Foam – Integral Skin (PHDM-IS): 10 – 20 lb/ft³ self-skinning flexible foam with excellent abrasion resistance, good elongation, low water absorption, and high tear strength. It suits noise barrier applications and is ideal for branding custom parts like floor mats. It is also often used for over-molding applications, like this heavy trucking challenge.
• POLYFORM® High Density Molded Foam – Non Skinned (PHDM-NS): 10 – 20 lb/ft³ open cell flexible foam with high resilience, good elongation properties, and good tear strength. It is formulated for low emissions and is suitable for broadband frequency absorption. Here is a medical device challenge that benefited from a non-skinning foam to reduce sound and fill space inside the device with a soft cushion.
• Polyform® Low Density Molded Foam – High Resilient (PLDM-HR): 3 – 6 lb/ft³ open cell flexible foam with high resilience, low fatigue loss, and good cushioning quality. It is suitable for absorbing mid to high-frequency sound waves, making it a preferred option for specific applications requiring good sound attenuation, thermal control, and cushioning.

Molded foam continues to amaze many industries for its versatility, durability, and effectiveness against noise,, extreme heat, and high impacts. Here are some of the ways our POLYFORM® custom molded foams can improve product quality:

• Heavy Trucking: Engine compartment components, headliners, floor mats, handgrips
• Marine: Engine enclosures, water sealing, structural fillers, cabin liners, trim cushioning
• Medical: pump insulation, blower compartments, medical-grade cushions
• Military: Tactical gear padding, engine compartment components, structural fillers
• Appliance: Motor insulation, structural fillers, compressor components, handgrips

Maximize Product Quality and Streamline Production with PMP

PMP is responsible for helping OEMs find the right molded solutions for their products. Getting started is easy and usually begins with a conversation with a PMP expert. In this ideation stage, we’ll brainstorm and visualize a successful project and determine a suitable foam. Expect a lot of questions to help us map out how we can get your project concept to go from good to great.

From there, our experts walk through your design and development process to uncover gaps and issues that molded foam may be able to solve. We will then develop a prototype using a method to mimic the molded design and test it to see how the product functions. We will finalize the design using those results and feedback from your stakeholders. You can learn more about our molded foam process here.

Molded foam offers precise yet flexible solutions to enhance your product design, simplify your assembly process, and ensure the project exceeds your expectations. If you’re ready to think forward and forge your path to a better product for your customers, contact us today.