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Foam Forming Services
Our Custom Foam Forming Service
NOBLE provides customized foam molding solutions at very competitive prices. From prototyping to manufacturing, we have a variety of state-of-the-art foam molding machines and sophisticated testing equipment. Under the guidance of a skilled team of professionals, we ensure you get high-precision foam molding parts with complex geometries. Please upload your CAD file and get an instant quote. Get high-quality precision foam molding parts within a few days.
- Advanced Equipment & Cost-Effective Price
- 10+ years of Foam Forming Services
- ISO 9001 & ISO13485 Certified Factory
- 100,000+Parts Manufactured
- Fast Turn-around Production
- 100% Inspection
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Our Powerful Foam Forming Processes
We provide customized foam molding solutions at competitive prices. With our advanced foam molding equipment and experienced engineering team, we can ensure that you receive high-precision, complex, and stable parts. Try our precision foam molding services and become our next satisfied customer.
Mixing polyurethane foam with a chemical catalyst to expand and harden it into a moldable foam. It is widely used in automobile and furniture parts for its flexibility and durability.
- Tolerances Down to ± 0.0003 In.
- Competitive Price 30% Cost Save
- Fast Turnaround in 7 days
- Quick Turn Milling Services
A mixture of foam resin and blowing agent is injected into a mold. After injection, the foam expands and takes shape inside the mold. It is widely used in automotive dashboards, packaging, and appliance insulation due to its high mass production efficiency and the complex geometries it allows.
- Tolerances Down to ± 0.0002 In.
- Quote Within 24 hours
- Fast Turnaround in 7 days
- Quick Turn Turning Services
The foam is placed in a heated mold cavity, and then the mold is compressed to force the foam material to take the shape of the mold. Due to its uniform density, it is widely used in foam gaskets, automotive seals, and industrial products.
- State-of-the-art Equipment
- 10+ Years of EDM & Wire-Cut
- Fast Turnaround in 7 days
- 1-to-1 Quote Analysis
It uses compressed air to squeeze the foam resin into a hollow shape. The resin is usually mixed with a blowing agent to make it expand and form a honeycomb structure when blown into the mold. It is widely used in automotive and toy parts due to its good impact resistance and lightweight hollow foam structure.
- Tolerances Down to ± 0.0005 mm.
- Competitive Price 30% Cost Save
- Fast Turnaround in 7 days
- Quick Turn Grinding Services.
The process heats a sheet of foam material until it softens, then applies a vacuum to draw it into a mold. The foam takes the shape of the mold as it cools and solidifies. It is widely used in protective covers and automotive interior parts due to its low mold cost and simple operation.
- Tolerances Down to ± 0.0005 mm.
- Competitive Price 30% Cost Save
- Fast Turnaround in 7 days
- Quick Turn Swiss Machining Services.
The process injects a mixture of foam resin and blowing agent into a mold. After injection, the foam expands and takes shape inside the mold. It is widely used in automotive dashboard packaging and home appliance insulation due to its high mass production efficiency and good dimensional control.
- 10+ Years of CNC Routing
- Competitive & Affordable Price
- 100% Part Inspection
- Fast Turnaround in 7 days
Our Robust Foam Forming Capabilities
From Prototyping to Manufacturing
NOBLE is your trusted one-stop custom manufacturing solution, from prototype design to manufacturing, through huge manufacturing resources, suitable technology, streamlined process, expert guidance, and a perfect quality inspection process to turn your ideas into reality.
Mold Manufacturing
After mold design approval, we start manufacturing the mold. Then produce samples to test whether they are qualified.
- Free DFM Feedback
- Quote Within 24 hours
- Fast Turnaround in 7 days
- 10+ Years of Mold Making
- State-of-the-art Equipment
- Competitive & Affordable Price
Low-Volume Manufacturing
With advanced production equipment and an experienced team of engineers, we can manufacture products with complex geometric shapes and high precision requirements with strict tolerance control and perfect quality inspection processes.
- Competitive & Affordable Price
- State-of-the-art Equipment
- 10+ Years of Low-Volume Manufacturing
- Fast Lead Time
- 30+ Countries shipped
- 100% Part Inspection
Medium & Mass Production
NOBLE meets mass production needs through strict tolerance control, quality inspection, and a complete supply chain, and quickly delivers cost-effective, high-precision parts.
- 10+ Years of Medium&Mass Production
- Competitive & Affordable Price
- Large Supplier Network
- 100,0000+ Unique parts produced
- Guaranteed Consistent Quality
- Fast Turn-Around Production
Why Choose Us for Custom Foam Forming Services
By collaborating with our experts, who have over 10 years of experience in foam forming, you can receive guidance on parts design, material selection, and finish choices. This ensures a smooth transition from prototyping to production. Our parts last longer than similar products due to their high precision and quality. As a result, NOBLE has received praise from customers worldwide.
Work with Us in 4 Simple Steps Only
With years of manufacturing experience, NOBLE provides the best solutions for all foam molding and small-batch manufacturing needs. We simplify the innovation cycle into four simple but effective steps.
Advantages of Foam Forming
Foam forming offers numerous advantages, ranging from weight and energy cost reduction to high customization and environmental benefits. NOBLE specializes in custom-molded foam and tooling for a wide range of applications. We can create molded foam for everything from low-volume medical mattresses to plastic parts.
Our Foam Forming Procedure
Foam forming is a complex process that requires skill and experience. While every case is unique, a typical mold order might look like this:
DFM Analysis
As soon as the customer confirms the mold order, we will begin an initial analysis of the parts to understand the part line, gate positions, etc.
Build product data drawings
The second step involved using predictive modeling software, which allowed us to understand how the molten material would behave as it entered the mold, enabling us to further improve the design.
Mold Making
Using high-quality machining equipment, we create the first molds as prototypes based on the raw materials chosen by the customer.
Mold Filling
The foamed polymer mixture is poured into molds, where it expands to form a part with a specific shape and a T1 sample.
Improve if Necessary
Based on our analysis of the T1 sample, we review the mold design and make any adjustments needed.
Commence Production and Shipping
We manufacture the molds in accordance with the final specifications, and after the final confirmation, we ship them to the customer.
Foam Forming Tolerances and Standards
The precision tolerances of our advanced foam molding equipment meet industry standards, ensuring that each part is always accurate and fits perfectly with other components.
| Standards | Description |
| Structural Foam Wall Thickness | Over .25 in |
| Structural Foam Part Length | Up to 7.5 ft. |
| Structural Foam Part Width | Up to 5 ft. |
| Structural Foam Part Height | Up to 5 ft. |
| Structural Foam Part Weight | Up to 150 lbs. |
| Structural Foam inspection | Large micrometers Custom go/no-go gaging |
| File Formats | MasterCAM SolidView/Pro CAD Readers |
| Industry Standards | ISO 9000 Compliant ISO 13485 Compliant ASQ Certified QA Staff NSF IAPMO UL |
Materials for Custom Foam Forming
Custom foam forming uses a variety of materials to meet the specific requirements of different industries. Here are some common materials used in foam forming, along with their key properties:
Polypropylene Foam (PP Foam)
PP foam is lightweight, durable, and chemical-resistant, offering high strength-to-weight ratio. It’s used in automotive, packaging, and industrial applications for impact resistance and insulation.
Polyethylene Foam (PE Foam)
PE foam is a closed-cell material with excellent impact resistance and durability. Commonly used in packaging, protective materials, and sports equipment, it’s versatile and cost-effective.
Aluminum Foam
Aluminum foam is lightweight, strong, and energy-absorbing, ideal for automotive, aerospace, and industrial use. It provides structural integrity and impact resistance through powder metallurgy or foaming agents.
Titanium Foam
Titanium foam is lightweight, corrosion-resistant, and porous, used in aerospace, medical, and high-performance applications. Produced via powder metallurgy or additive manufacturing, it offers superior strength and durability.
Surface Finishes for Foam Forming
Foam molding includes metal foam molding, plastic foam molding, etc. The surface treatment of the mold is usually completed during the production process. After the foam molding is completed, we will perform certain surface treatments on the finished product according to your requirements.
Glossy
A grade finishes are made using a diamond buffing process and yield shiny and glossy surfaces on injection molded parts.
Semi-glossy
B grade finishes use grit sandpaper to produce parts with a slightly rougher finish than grade A parts. Custom molded plastic parts that undergo B grade finishing have a matte surface texture.
Matte
C grade finishes use grit sanding stones to produce a rough, uneven surface. Injection plastic parts that undergo C grade finishing have a matte surface texture.
Textured
D grade finishes use grit and dry glass beads or oxide to produce a very rough textured finish. Depending on the type of material used, products can have a satin or dull finish.
Quality Inspections for Our Foam Forming Services
NOBLE’s experienced engineers have the expertise and experience to meet your specific needs, can undertake complex and challenging foam molding projects, and strictly implement our strict quality inspection process to ensure that you get low-cost, high-precision foam molding parts.
- Material Certificate
- Free DFM Design Feedback
- Weekly Mold Progress Report
- Trial Mold Parameter & Video Supplying
- T1 samples Inspection Report
- Inspection Report Before Shipment
Custom Foam Forming Parts Display
Check out our over a decade of precision custom foam forming parts, including precision foam forming prototypes and parts from our valued customers.
See What Our Customers Say About Us
NOBLE has been engaged in foam forming services for over ten years and has served many overseas customers. Customers’ words are more substantively representative than the company’s statement–see the objective evaluation of our satisfied customers.
John Matthews
Senior Engineer
We were facing challenges in designing lightweight yet durable packaging for fragile medical devices. NOBLE’s foam forming technology allowed us to create custom foam inserts that perfectly fit our products, providing superior protection during shipping. Their team really understood our needs and offered innovative solutions.
Carlos Ramirez
Founder & CEO
As a startup, we needed rapid prototyping services for a new consumer product. NOBLE’s ability to produce foam components quickly, with minimal lead times, allowed us to iterate and bring our product to market faster than we anticipated. Their responsiveness and flexibility were key to our project’s success.
Sarah Knight
Procurement Director
We were initially concerned about the costs of foam forming for large-scale production, but NOBLE’s pricing was very competitive. They were able to optimize production processes to reduce waste, making it a cost-effective solution for our automotive parts. The quality, combined with the cost savings, made the partnership a win for us.
Linda Park
Operations Manager
The team at NOBLE is responsive, knowledgeable, and always available to discuss project details. From the initial consultation to the final delivery, they ensured everything went smoothly and on schedule. Their customer service is top-notch, and we’ve always felt supported throughout our projects.
Tom Harris
Supply Chain Manager
We’ve been working with NOBLE for over 5 years now, and their consistent quality and service have made them an invaluable partner. Whether it’s custom foam components for new designs or maintaining large production orders, NOBLE always delivers. We’re excited to continue growing together.
Applications of Foam Forming
Foam forming is used across industries to produce lightweight, durable components. Its applications include automotive weight reduction, medical cushioning, and aerospace insulation, all enhancing performance and efficiency. NOBLE’s expertise ensures foam parts are lightweight, cost-effective, and meet the high-performance standards of these sectors.
Automotive Parts
Foam forming reduces weight in automotive components, improving fuel efficiency. It’s used for sound insulation, seat cushions, energy-absorbing parts, and interior panels, enhancing safety, comfort, and performance.
Medical Devices
Custom foam components provide cushioning, insulation, and protection for medical devices. They improve patient comfort, safeguard delicate instruments during transport, and ensure functionality in equipment like orthopedics and diagnostic tools.
Aerospace Parts
In aerospace, foam forming creates lightweight, strong parts for structural components, insulation, and impact absorption. It reduces weight, boosts fuel efficiency, and protects sensitive parts during storage and transportation.
Robotics Industry
Foam is used for protective casings, cushioning, and lightweight internal components in robotics. It safeguards electronics, provides insulation, and contributes to the durability and efficiency of robotic systems and parts.
Consumer Electronics
Foam protects consumer electronics like smartphones and laptops, providing shock absorption, thermal insulation, and static protection. It’s also used in packaging to ensure safe transport and in internal components for improved performance.
New Energy
Foam forming supports renewable energy technologies by providing lightweight, insulating, and vibration-dampening components. It’s used in solar panels, wind turbines, and energy storage systems to improve efficiency and durability.
If you need a rapid prototyping manufacturer or foam forming shop for small, medium-volume, or mass-production products, NOBLE is a great choice. Our skilled team manufactures parts according to your drawings on modern foam forming machines, ensuring high accuracy and quality in all sizes. We also offer professional design support for your foam forming projects.
Get professional, fast service for your foam forming project. Upload your CAD files now for a quote!
