Posted by Nancy Grossbart
I was thinking back over my last ten years in the injection molded (EVA and polyolefin foam) business, and wondered which products made with this process are my favorites. It's an extremely hard question because there have been lots and lots of products made. Many products have been made by my company but other companies in our industry have also created incredible designs. If I had to narrow it down to only five, which five would it be?
It was hard to decide, but here's my list. I'm sure, however, that I will need to do another post for the runners up.
Crocs Sandals. The Crocs Sandal is the number one obvious choice. It’s not only because of the incredible (so ugly, it’s beautiful) design but because of the worldwide phenomenon it created. We were lucky enough to manufacture Crocs in our factory and it never ceased to delight me to watch them being made. After they came out of a hot mold, the sandals were cooled on a unit that looked like a ferris wheel, where each level held one cycle of production. Round and round they would go and, at the end of the cycle, they would be removed from the carousel. Straps were attached and "voila" a new pair of Crocs was born, in a rainbow selection of colors.
Backpack Padding. If you’ve owned a backpack, especially a high-end backpack, you probably never noticed the comfort-foam included in the product. Why? Because it was always hidden behind fabric or mesh. The ability to injection mold EVA and polyolefin foam changed all that. Here’s a backpack that is wearing its lumbar and upper back comfort-foam on the outside, as a showpiece. The detail of the injection molded foam process allowed for industrial design to not only deal with the practical, but also the beautiful.
Kayak Seat. Traditionally, kayak seats were made from compression molded foam with a fabric laminate. This product design has always had a limited life. Several years ago a few kayak companies were adventurous enough to recognize the durability and detail benefits that result from the application of the injection molding foam process. They designed kayak seats that were not only very detailed with undercuts and logos but extremely durable.
Carseat Armrest. Check out this really creative foam carseat armrest. The carseat manufacturer designed the armrest foam to be injection molded separately and allowed the foam to "shrink" onto a plastic substrate. The subtrate has ridges on it that create a "grip" relationship between the foam and the plastic. The results ended up utilizing the benefits of EVA/polyolefin foam in an armrest application that needed to be "kid friendly."
Construction Kneeling Unit. I don't know if I like this product more because of its design or because of its function. I'll bet if you just looked at the product on the left you would never know it was used in construction. 
This clever kneeling pad design allows workers to stay on top of a house during roof construction as they are installing one truss after another. The time savings in crane rental is up to 40%, paying for the product almost the first time it is used. The orange support is made of durable, powder-coated aluminum. The injection molded EVA/polyolefin foam padding provides comfort for knees and legs and stays dry during use.
If you have a favorite, I'd love to hear about it. If you send me a photo, I will be happy to post it. In the meantime, visit our product solutions gallery to see a selection of products we've made over the years
Posted by Nancy Grossbart
I love this story, even if we didn't make the “One World” soccer ball.
This soccer ball took 5 years to develop. I can believe it. I, absolutely, know how hard this soccer ball was to manufacture. I've worked on lots projects in the injection foam molding process that have required extensive R&D to make the product come out just right.
It all started when a music producer and inventor, Tim Jahnigen, saw how children traumatized by their violent environment “were desperate to play with anything.” It gave him the idea to create an indestructible soccer ball.
After 5 years of development, and some help from Sting, he developed a soccer ball with the injection foam molding process like Crocs sandals.
The soccer ball is indestructible because this soft foam is basically indestructible. How long have you worn your Crocs sandals? The soft foam has its own, extremely durable, skin that is formed during the manufacturing process. Inside the skin is an equally tough, closed cell, foam that won’t absorb liquid.
See how a truck can run over it and still not destroy it.
All of these process and foam benefits mean the kids will be able play with this ball in any environment with no chance of it being flattened, and almost no chance of it ever being damaged. I understand a ball was given to a lion in the Johannesburg zoo. Even he couldn’t destroy it.
You can learn more about it in an article in the San Francisco Chronicle.
Posted by Nancy Grossbart
It's amazing how much you can learn about subjects that you thought you had no interest in.
I majored in anthropology in college and never used any of it after I was graduated. My career had been exclusively in the marketing, advertising and graphic design area until 1999, when we came up with the idea to manufacture Injection Molded Foam parts with this incredibly unique process.
In the past 10 years on the job, I have gained a deep understanding of 3D geometry, production, quality, testing and standards, distribution/shipping and foaming materials.
Gaining this kind of knowledge is good for business because it allows you to walk and talk the talk. And if you are the least bit verbally adept, you will find potential customers asking you questions about your background that can shock you.
I have been asked more times than I can count if I am an engineer. This question has always made me laugh. Me? An engineer? Obviously, the answer is no but I must be doing and saying something right or why would people ask.
My favorite, however, is when Ron Snyder (Croc's CEO) asked me if I was a Polymer Chemist. OMG. That one really made me roar with laughter (on the inside). We were sitting on a boat in a Miami harbor beginning our relationship with Crocs. I was trying to remain professional so I didn't laugh out loud. At this point, I guess I had learned a lot about foaming materials, enough to "convince" a highly experienced and intelligent person to believe that I knew what I was talking about.
It's a perfect example that, if you want to, you can always step out of your comfort zone to learn the most complicated things.
I'd love to hear about the job you have that you were not qualified for when you started!
Posted by Nancy Grossbart
Polyolefin foam is a great material for kid's products. It works well in lots of applications from padding for sporting goods to sandals (Crocs) and now, products for kids.
To begin with, it's closed-cell. That means it's waterproof and won't absorb bodily fluids. It also means it resists mold and mildew because the bacteria has no place to reside.
It's so light that it floats and can be used for bath or pool toys and has no adverse chemicals so when kids put the toy in their mouths, there is no need to worry.
Polyolefin foam has a high tear and tensile strength so it can't easily rip and won't crack or peel. This means it will not only last a long time but, when kids put it in their mouths, it will pass the bite test.
The chemistry of polyolefin foam makes it resistant to most chemicals. This allows you to clean and disinfect it with any household cleaner keeping it safe from any surface bacteria.
Parts can be also designed with lots of features and benefits including molded-in logos and graphics. And can be made in extremely bright, attractive to kids, colors.
If you're wondering if it will pass the new CPSIA standards, it will!
MDI Products' offering of formulas known as PolyCellTM are phthalate free, PVC free, AZO dye free, with insignificant metal content. In addition to all the other reasons why it is great for kid's products, you can also be confident of its safety.
I'd love to get your feedback on what other specifications might be important for kid's products.
Download 8-page white paper on
"Understanding Flexible Foam".