Using EVA Foam Injection Molding to Bring Innovative Ideas to Life

Global Brands, Established OEMs, and Entrepreneurial Inventors Choose PopFoam

Pop Foam Products

Trusted by Global Brands

Why PopFoam?

PopFoam is an EVA Foam Manufacturer of Injection Molded Closed-Cell EVA Polyolefin Foam Products.

Our EVA Foam is lightweight, 100% waterproof, and is virtually indestructible. PopFoam makes proprietary compounds customized for each of our customer’s needs. Discover chemically resistant, non-toxic and durable molded EVA foam, with Popfoam.

The Go-To Source for Wheel and Tire Solutions

PopFoam expertly manufacturers injection foam molded wheels and tires
for strollers, walkers and more.

The Ultimate Guide to EVA Injection Foam Molding

Design is a complex process in search of a simple solution. Every product exists to either deliver a unique benefit or solve a specific problem. It’s up to designers to use every resource at their disposal to engineer that advantage.

A crucial part of that process is material selection. Materials must meet unique requirements for performance, size, cost, and production, and complicating matters even further, it’s not out of the ordinary for these factors to conflict with each other. As a result, designers are frequently forced to make compromises and settle for underwhelming options.

PopFoam is an injected molded foam material that empowers and innovates the design process. It’s waterproof, mold and mildew resistant, and buoyant, making it ideal for aquatic applications.  It also has greater tensile and tear strength than other foam materials, making it exceptionally durable yet lightweight. The range of hardness and color specifications is nearly limitless, and the production process enables unique design options.

For all these reasons and more, PopFoam makes designing great products easier than ever.

Featured Products

Monkii 360

The Monkii brand produces products to further their dive into functional fitness. 


WODA makes carrying stuff to the boat, the beach, the pool cool again!


HECOstix has taken a simple game of playing catch and added a twist!


Yes, a foam injection molding company, has provided top-quality results with its decades of experience, exclusively on foam injection molding. The key differences: thermoplastic Injection molding uses high pressure to fill the mold while foam injection molding uses very little pressure. Also, where thermoplastic injection molding uses a single steel mold, foam injection molding utilizes multiple foam molds made of aluminum in a multi-station machine. Finally, thermoplastic injection molding utilizes mechanical ejection while the PopFoam self-ejects. Contact us today for more on our molding foam process!

We’re happy to provide rough quotes and a product cost breakdown for custom-molded foam products. Contact us with your idea and we will discuss foam fabrication details.

Assuming that your CAD file only requires minor revisions from our development team, production of your specialty foam products can start in as little as 4-6 weeks. Too long? Ask about our expedited schedule, product design, and prototyping.

They’re quite different. Injection-molded EVA foam is more durable and offers more potential for detail and will generally last longer. Compression-molded parts tend to be used for expendable uses with short lifespans. When you engineer a part with injection-molded foam, it is meant to last a lifetime.

We always want to hear from entrepreneurs and inventors with creative foam products. We have worked with many start-ups that have used Kickstarter or other crowd-funding sources to assist them in launching a new product or design. Our experienced technical sales reps, engineers, mold makers, and factory will give you help in designing your part in PopFoam.

Yes. Various ranges of compounds and expansion rates are considered to make a part soft or firm, decoration, color according to your requirements. Contact us today for more information on creating firm or EVA soft foam!

No, due to the expansion process we cannot put anything inside the foam molds. However, we can offer undercuts. For more information on our EVA foam manufacturing process or mold undercuts, contact us today!

Yes, PopFoam is a closed-cell foam material. All of PopFoam’s cell structures are interconnected, keeping all liquids out. Contact us for more on our EVA closed-cell foam.

As an EVA foam manufacturer, we generally manufacture parts up to 24” x 32”. Need a larger size or have special requirements to cut foam to size? Please check with us for creative design solutions and any product size limitations.

Yes. Our compounds for our durable foam products are crafted with chemical-resistant materials and are resistant to most household chemicals and cleaners.

Yes, creating a very durable surface and a tough foam. Our compounds for custom-molded foam products also offer incredible tear strength.

Click here to view our Foam Texture Library regarding our injection foam-making process.

Ready for Launch?