Our comprehensive design guide provides valuable information to help you select the right foam materials and design effective solutions for your specific application requirements.
Learn about our design expertise and engineering support
Designing with foam materials requires careful consideration of various factors to ensure optimal performance in your application. Our design guide provides valuable insights and best practices to help you create effective foam solutions.
Our engineering team is available to assist you throughout the design process, from material selection to production scale-up, ensuring your foam components meet all performance requirements.
We specialize in developing custom foam solutions tailored to your specific application requirements. Our team works closely with you to understand your needs and create solutions that deliver optimal performance.
When designing foam components, consider these key factors to ensure optimal performance and manufacturability.
Choosing the right foam material is critical for optimal performance in your application.
Precise dimensional tolerances ensure proper fit and function in your application.
Proper adhesive selection ensures strong, durable bonds between foam and substrate materials.
Designing with manufacturing processes in mind ensures efficient production and consistent quality.
Our structured design process ensures efficient development of foam solutions that meet your requirements.
We work with you to understand your application requirements, including performance specifications, environmental conditions, and cost targets.
Based on your requirements, we recommend appropriate foam materials and adhesives that will provide optimal performance in your application.
Our engineering team develops detailed designs for your foam components, considering manufacturability, assembly requirements, and cost optimization.
We create prototypes of your foam components for evaluation and testing, allowing for design refinement before full-scale production.
We conduct comprehensive testing to validate that your foam components meet all performance requirements and specifications.
Once the design is validated, we transition to full-scale production, implementing quality control procedures to ensure consistent product quality.
We offer a comprehensive range of design services to support your foam component development needs.
Our engineering team provides comprehensive support throughout the design and development process.
We offer rapid prototyping services to help you validate your design before full-scale production.
Our comprehensive testing capabilities ensure your foam components meet all performance requirements.
We provide seamless transition from prototype to full-scale production with consistent quality.
Practical tips to help you design effective foam components for your application.
For applications requiring long-term sealing or cushioning, select foam materials with good compression set resistance to maintain performance over time.
Design with appropriate tolerances based on the foam material properties and manufacturing process to ensure proper fit and function.
Design parts to maximize material utilization and minimize waste, considering the nesting capabilities of the manufacturing process.
Account for temperature, humidity, UV exposure, and chemical exposure in your material selection to ensure long-term performance.
Consider how the foam component will be assembled into the final product, including alignment features, adhesive application, and handling requirements.
Create prototypes early in the design process to validate performance, fit, and manufacturability before committing to full-scale production.
Our engineering team has helped numerous customers develop effective foam solutions for challenging applications. Here are some examples of our successful design projects:
Challenge: A major automotive manufacturer needed a custom sealing solution for a new HVAC system with complex geometry and tight space constraints.
Solution: Our engineering team developed a custom die-cut foam gasket with precise dimensions and material properties tailored to the application requirements.
Result: The solution provided excellent sealing performance, met all dimensional requirements, and reduced assembly time by 30%.
Challenge: An electronics manufacturer needed a protective packaging solution for sensitive components that would provide shock absorption and ESD protection.
Solution: We designed a custom foam insert with varying densities to provide optimal protection for different components, incorporating ESD-safe materials.
Result: The solution reduced shipping damage by 85% while maintaining ESD protection and optimizing packaging size and weight.
Our collaborative design process ensures that we understand your requirements and develop solutions that meet your needs. Here's how we work with you:
We discuss your application requirements, performance specifications, and design constraints to understand your needs.
Our engineering team develops initial concepts and material recommendations based on your requirements.
We refine the design through collaborative feedback and prototyping to optimize performance and manufacturability.
We validate the design through testing and analysis to ensure it meets all performance requirements.
We transition the validated design to production, implementing quality control procedures to ensure consistent product quality.
Access our comprehensive design resources to help with your foam component development.
The Advanced Quality and Design Planning Guide is offered as an indicator of our focus on customer satisfaction among engineers and quality personnel. It represents 60 years of experience in terms of "best practices" for the design, release, and use of efficient fabricated products, including those made from materials other than foam.
Click on the image of the sample board to view its contents. Plastomer offers a design guide to help customer engineers. CLICK HERE to request a hard copy of the guide or a sample board be mailed to you.
Contact our engineering team to discuss your foam component design needs and how we can help you develop effective solutions for your application.
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