Design

Unleash Your Imagination

Let PopFoam be your injection molding design guide! From extreme undercuts to floating cores, turn your foam designs into reality, no matter the complexity. Because of our distinct injection molded foam, PopFoam allows you access to complex geometry without needing complex tooling, and achieve lighter molded foam products with more efficient production.

  • Undercuts

    Internal/Female undercuts can be added into the part design. However, external undercuts are not possible in injection molded foam

  • Drafts

    Most part foam designs require a minimum of 5 degrees of draft or radius to self-eject.

  • Floating Cores

    Molded foam products with internal undercuts, deep cavities, internal details and complex geometry can often be completed with a floating core.

  • Part size

    Smaller molded foam products molded of PopFoam are often not economical to produce. We suggest minimum part sizes be greater than 2 square inches. Larger sizes can be up to 30” by 26” by 14” with a maximum weight of 2,800 grams.

  • Tolerances

    Since PopFoam is a soft compound that expands from tooling, many factors influence the amount of tolerance required. We will work with you to develop a process control plan.

  • Parting line

    With our foam injection molding, our engineers will help you to determine the optimum locations for the parting line and gate locations as it relates to the part’s appearance and production.

  • Wall sections

    Though common wall sections range from .25” to .6”, some foam designs can be as wide as 2”.

  • Environment

    PopFoam is a proprietary closed-cell and cross-linked material that resists mold and common cleaning chemicals, and floats. We are a foam manufacturer that can deliver a versatile range of products.

  • Texture, Text and Logos

    PopFoam can accommodate a wide variety of molded foam products! Subtle shapes can either rise from, or recess into, the body of the part.

To begin, Download our Design Guide now, and unleash your imagination.

To get started, send our design team your CAD file, or reach out for full service, from concept to reality. We’ll help you make the most of your investment.