Direct injection expanded foam molding

[1] This process eliminates the steps normally required for die-cutting and compression molding, because 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).

Unlike a sponge, foams from this process are closed-cell, meaning it's waterproof and resists mold, mildew, and bacteria from entering the material.

It is also cross-linked, which means that the cells are connected in a way that makes the foam strong and durable with high tear and tensile strength.

This requires the mold cavity size to be smaller than the final part.