There are two typical processes used when it comes to manufacturing foam products. Today, we will focus on compression molding (or foam molding). With foam molding, the material is usually preheated and placed in a mold cavity, which is then closed before pressure is applied and the foam material if forced into all of the molds necessary nooks and crannies. You can also get the information about stretch forming presses through various online sources.
The material typically used for foam molding is a thermosetting resin, added in a partially cured stage as either a granule, preform, or putty-like substance. The advantage here, as opposed to other manufacturing methods, is that compression molding is capable of intricately molding large and small parts with a high degree of precision.
At the same time, compression molding is also cheaper than many other methods, without wasting nearly as much material as other processes. This makes foam molding highly favorable, especially when expensive compounds are being used.
Foam molding was pioneered primarily to manufacture parts to replace metal parts in various applications. For other applications, it was used to quickly and cheaply form foam and plastic to be used for protection, covering, shipping, containment, and more. When foam molding is not used to replace metal parts in various applications, it is frequently used to create soft protective coverings and inlays such as case inserts for fragile part and products.
Those are also the result of custom contour cut compression molded foam. You could find numerous examples of compression molded foam in your day to day life, these are just a few – but next time you feel something soft, think about the many ways compression molded foam might be helping or even protecting you every day.