Promotional foam

Moulded Foam Products

Promotional foam

Moulded Foam Products

If you’re looking for a promotional or retail item with a precise shape and consistent finish, moulded foam products can be an excellent solution.

Moulded foam products are items created by heating foam and then using custom moulds to shape it into the desired form. Unlike standard cut-to-size foam, this process creates intricate, 3D shapes with smooth, durable outer skins. The range of products this process can produce is almost limitless, but it is particularly popular for toys (e.g., frisbees), swimming aids, gym equipment, and a range of medical and healthcare products. Moulded foam can also be suitable for industrial applications.

At Polyformes, we manufacture bespoke moulded foam products using a range of specialist materials and forming techniques. Whether you need a simple moulded component or a complex custom-designed product, our team can help you select the right material, design, and manufacturing process to achieve the best results.

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Competitive pricing

Advantages

Benefits of moulded foam

The benefits of using moulded foam include:

Suitable for complex 3D shapes.

High-quality, smooth surface finishes.

Lightweight for ease of use.

Durable and long-lasting.

Consistent, repeatable shapes and quality.

Available in a range of materials, densities and colours.

Low unit price (after initial tooling costs).

A child looking at custom moulded foam products in a toy shop

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FAQs

Moulded foam toys made from premium materials like EVA or Polyethylene are rigorously tested to meet global toy safety standards (such as EN-71 or ASTM F963). This certification ensures the foam is free of harmful substances, including heavy metals, phthalates, BPA, and formamide.

Moulded foam products typically use a dense, highly resilient foam, such as EVA (Ethylene-Vinyl Acetate) or Polyethylene (PE). EVA is a tough, rubbery, closed-cell foam that provides a premium surface finish and texture. Polyethylene foams, such as Plastazote®, provide good all-around performance, longevity and appearance.

Moulded foam is created by heating foam material and then using a mould to form the required shape. This process typically leaves a smooth skin on the outside. This skin, alongside its improved appearance, also makes moulded retail products (such as gym equipment or toys) highly durable, waterproof, and easy to wipe clean. In contrast, cut foam uses CNC routing, sawing, and waterjet processes (among others), all of which leave the cell structure visible.

Moulded foam products are suitable for use in outdoor applications. Closed-cell foam materials do not absorb moisture and, due to the skin formed during moulding, are easy to wipe clean if required. Prolonged exposure (over a period of years) to UV may, however, start to cause the material to degrade, whilst darker colours may also fade.

A doctor handing a moulded foam product to a patient during a consultation

Process

A partnership approach

We don’t just manufacture moulded foam products – we gain a detailed understanding of our business and challenges before proposing a cost-effective solution that does exactly what you need.

Understanding

We discuss your requirements with you, gaining a full, detailed understanding of your project.

Develop

Using your products or CAD data, we develop a solution using appropriate materials.

Test

We provide pre-production samples for testing and assurance on fit and quality.

Manufacture

We manufacture your products in-house at our specialist foam conversion facility.

Support

We forge long term relationships, providing ongoing support and assistance.

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Why work with us?

At Polyformes, our experience, expertise, and in-house conversion equipment enable us to provide your business with a wide range of benefits.

UK manufacture

We manufacture your custom foam products ourselves, allowing us complete control over design, quality, and lead times.

Short lead times

Our process – from initial meeting through design concept, samples, testing and manufacture – is quick, easy and focused on your requirements.

Foam experts

You can rely on our team of knowledgeable, experienced foam experts to select the optimal foam material, design, and production method for your application.

Single source

As part of Macfarlane Packaging, you can source a huge range of additional packaging and products from a single, easy-to-manage source.

Vast experience

Our approach means we’ll always consider your budget and balance this against the required performance and technical considerations.

Sustainability

As well as using recycled material where possible, we also place a strong emphasis on removing unnecessary materials, weight and volume from your products.

Wide range of options

Similar foam products

Disclaimer: Generative Ai may be used on this site when specifically creating content and information relating to the products, processes and materials we use at Polyformes. Any Ai content undergoes stringent reviews and editing by humans to check accuracy. Please view this content policy for further details.

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If you need high-performance foam inserts, packaging, products or materials, we can help. Please contact a member of our team for a free consultation and quote.

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The information on this page was written and checked by our team of experts. You can contact them to discuss your requirements, or for any questions you may have, using the details here.