Foam Molding into Plywood Shell

Lightweight furniture is difficult to make to be structurally sound. Foam Molding is a way of expanding foam inside a cavity using steam to push it through.

Foam Molding can be applied to Plywood veneers that have been assembled out of net shapes. An example of net shapes is a flat cardboard box before it is folded into a cube form. Complex shapes like stools and chairs can be formed. Once assembled, a similar foam to insulation that can be bought in a spray can is injected into the shell of the plywood. Inside the shell the polyurethane foam expands and becomes rigid once the material cures.

After curing the piece is ready for use!