Molded Foam Implementation and Production Process

STAGE 1 - Design

Based on your 3D documentation, we'll prepare a quote for foam production and the necessary molds. If you don't have such documentation, we'll create a digital model based on the design you provide, most often using a 3D scanner.

Once our offer is accepted, a production mold and the first prototypes will be created. The foams are made using proprietary formulas, and parameters such as hardness, density, and flammability are individually tailored to the customer's expectations.

STEP 2 - Acceptance

STAGE 3 - Production

We send the first polyurethane foam prototypes to you for quality and hardness approval. Once we receive approval, we launch mass production.

Advantages of Molded Foam

When we compare molded foam with the traditional solution of cut foam, it turns out that cut foam generates hidden costs that significantly increase the final bill. Why?

Complex process: Cut foam requires numerous additional steps: cutting, gluing, and waste disposal. Each of these steps generates costs related to tools, consumables, and labor time.

Material losses: Cutting foam creates large amounts of waste that must be disposed of. This is an additional cost, both financial and environmental. Administrative costs: Managing a multi-step process requires more administrative resources. Warehousing costs: Cutting foam, semi-finished products, and waste take up significant warehouse space, generating additional costs.

Molded foam, on the other hand, offers numerous benefits: Efficiency: The entire production process is significantly shorter because the foam is molded in a single step. This translates to a 100%+ increase in productivity. Quality: Molded foam ensures high quality and consistent product consistency. Waste Minimization: Thanks to precise molding, waste is minimal or nonexistent. Cost Reduction: By eliminating multiple production steps, we significantly reduce costs related to tools, consumables, labor time, and storage. Flexibility: Molded foam allows for the creation of products of any shape and size, which expands design possibilities. Bottom Line: Although the initial investment in molded foam may seem higher, it proves more cost-effective in the long run. By eliminating multiple production steps, reducing waste, and increasing efficiency, molded foam is an investment that quickly pays for itself. Environmental Aspects: Reduced waste and lower energy consumption translate into a lower environmental impact. This text combines a clear presentation of facts with an emotional appeal to rationality. It shows that molded foam not only means lower costs, but above all, greater efficiency, quality and production flexibility.