Posted by Nancy Grossbart
Lately, I find myself waxing philosophical about great product design and what it really means. I voraciously devour articles and blogs on the subject, finding that the writings that affect some inner space inside me are the ones that make the most sense. Knowing great product design is probably more emotional than anything else.
Dan Harden's article at Fastcompany.com about the Disappearing Act of Good Design affected me that way. In his blog, he says.
When a product is so completely and rightly designed, it has aesthetic and functional elements that are clearly stated and obvious. The product itself communicates without words its utilitarian value, ease of use, and beauty, and you perceive the quality-contributing elements instantly.... When a product does all the above things well, instead of it having abundant presence like one would expect, it actually sort of disappears when you use it.
What this means to me is the best product designs are ones you love instantly and then take for granted (in a good way) after you incorporate them into your everyday life. Harden uses the examples of the iPhone, a Porsche, an Aeron Chair. All of these are great designs that we admire whether we own one or not.
As a manufacturer of injection molded polyolefin and EVA foam, we have worked with some really great product developers and product designers. One customer, in particular, made the development process extremely difficult by creating five different designs (five molds) over a two to three year period before settling on the final design. As you can imagine, from a manufacturer's perspective, we were both frustrated with the process and anxious to be in production. However, when the 5th design came out of the mold, it was astoundingly beautiful both in aesthetics and function. It was hard to remember ever being frustrated, which only emphasizes Harden's take on this.
There is unity and wholeness, and it is so evident that this thing will totally satisfy a physical and/or emotional need....The product becomes a subconsciously satisfying experience, not a heavy conscious thing that demands attention because it's pretty or different...
I recently heard a story about Holly Hunter, the Academy Award Winning Actress, who is starring in the TV series "Saving Grace". One of the directors is a friend of a friend. The director said "She is so frustrating. I have a budget to meet and every time I OK a scene, ready to move on, Holly always asks for one more take insisting that she can do it better. Reluctantly, I agree and every time she is right. She adds that something extra that makes it amazing."
Obviously, this doesn't relate directly to product design or molded foam or foam manufacturing. It does, however, relate to the truth that when creativity is right, it's just right.
Posted by Nancy Grossbart
Part of my daily web meanderings take me down the path of looking at new product designs and concepts. If you follow me on Twitter (@foamentingideas) you will see that I am apt to share these "finds." Yesterday I came across a unique bathroom tile with the towel hook built in. 
It was designed by Czech designer Vadim Kibardin. I liked it immediately as it was both innovative and very practical. How many times have you been in the shower and wish you had easy access to a towel? It's a thoughtful, beautiful design as is but (being in the foam business) I suddenly realized "this design could have been made of injection molded foam."
I know this sounds like a commercial but, I swear, it's not. Don't you agree that foam tiles on the shower walls wouldn't be a great idea?
Imagine it could be both colorful and protective at the same time. Because this foam is closed cell it wouldn't absorb any of the water. Plus the base resin is chemically resistant, allowing you to keep it clean with any regular household cleaner.You could even mold logos and textures into it.
I will probably come across lots of products that fit the "It Could Have Been Made From Foam" description. When I find them, I'll talk about them. If it feels like a commercial then I'll, at least, try to make it a commercial worth watching.
Posted by Nancy Grossbart
When my company (MDI Products) first began to work with product designers who wanted to create a foam product and had lots of plastic molding experience, it was very difficult to get them to "think differently" about how to design a product that took advantage of our
injection molded foam process. There are only some things about both processes that are similar. Both plasticize raw materials in a hot barrel. Both inject in the materials into a closed mold. Pretty much the similarity stops there.
Understanding the fundamentals is key to designing a great part. To really comprehend what is happening, you need to first know that injection molded foam is actually a foam manufacturing process which manufactures foam in the shape of your part.
The next area to understand that, unlike the single mold plastic process, the machines used in the injection molded foam process are multi-station presses, which utilize multi-molds.
Again, unlike plastic injection, the mold cavities are designed smaller than the final part size. The parts expand rather than shrink. The amount of expansion is dependant on the material softness you require.
The material remains in the heated mold during the cross-linking or cooking process. The cooking time is dependent on the thickness of the part. The mold opens very quickly when the cooking is complete. The part expands and explosively self ejects from the mold cavity. The part is removed from the mold station and set to cool.
Learn more about self-ejection, draft, corners, edges, and undercuts later.
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".