Molding/Pouring

The Molding/Pouring stage covers the physical forming of the foam material to prepare it for use in product assembly. Molding/Pouring is a multi-select Production Stage and more than one process can be selected. Most processes are applicable to all Foam materials.

• Injection molding, for foam is the default selection for all Foam materials except polyurethane foam. This process should be selected when the foamed material is in liquid form and injected into a pre-made mold, cooled, then removed and trimmed.
• Die cutting, from sheet stock should be selected when the foam material is prepared into a sheet of foam and then cut into shape, typically with a flatbed or rotary press.
• Die cutting, from sheet stock, two times should be selected when the Die cutting, from sheet stock process is performed twice to achieve the final shape required for product assembly. For instance, if a footwear insole is cut to a generic size prior to molding and then cut again to fit the specific shoe size, the Die cutting, from sheet stock, two times process should be selected.
• Molding, compression should be selected when the foam material is shaped by being placed into a heated mold and compressed.
• Molding, compression, two times should be selected when the Molding, compression process is performed twice to achieve the final shape required for product assembly.

Polyurethane foam has an additional Molding/Pouring process option:

• Pouring, bulk, for foam is the default selection and represents forming by bulk pouring. It is common for a polyurethane material to be bulk poured to create a sheet, followed by additional Molding/Pouring steps to prepare for product assembly.