Direct injection expanded foam molding (also known as injection molded foam) is a foam manufacturing process that creates soft foam products direct from compound into a final product. This process eliminates the steps required for die-cutting and compression molding, as it manufactures the foam and the product simultaneously.
The base resin used in a complex formula, is an ethylene-based polyolefin elastomer (like polyethylene and EVA). Foam manufactured with these resins has many physical benefits. Unlike a sponge, foams from this process are closed-cell, meaning it’s waterproof and resists mold, mildew and bacteria from entering the material.