Foam Molding

Foam molding takes small plastic pellets, then steams and adds pentane gas to make them up to 40 times their original size. After the pellets have expanded, they are re-heated and steam is used to inject them into a mold. This process creates light objects with low density, a lot like packaging peanuts.

Foam molding works pretty fast, usually 1–2 minutes to create each object. It creates various light-weight items like bicycle helmets, packaging supplies and surfboards. Foam molding is excellent for objects that need to be light but also large.

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