We design and manufacture most trim and fabrication tooling, as well as assembly fixtures, in-house. We’ll occasionally build prototype and production molds in-house, but we’ve found it’s usually more cost-effective to design in-house and partner with a dedicated, US-based moldmaker for the manufacturing.

What makes the XL EXTRALIGHT® material exceptional are its versatility and incredible properties. Our R&D laboratories work relentlessly on the use of the most technologically advanced Polyolefin resins on the market. The materials Foam Creations develops have wide properties range compare to regular cross-linked foams, available in other parts of the world. That is the reason why XL EXTRALIGHT® injection foam molding products have so much success all over the world.

From concept to production, our tailored design and engineering capabilities deliver cost-effective solutions for two-shot injection molded parts. We have the experience and confidence to take full design responsibility or serve as a design partner.

XL EXTRALIGHT® injection foam molding technology is a patented product created by Finproject Group. Foam Creations, a now well-known foam molder, was the first company in North America to import the expanded and cross-linked foam injection molding technology from Italy.

This breadth of experience enables us to evaluate multiple processes and materials and recommend the optimal combination for your unique application.

We’ve worked with hundreds of materials and additives, so we can accurately predict how processing will affect appearance. This expertise allows for precise color-matching and replication of design intent, enhancing visual appeal and brand identity.

Our specialized press-to-press transfer technique allows us to mold 360-degrees. It’s ideal when your application requires molding over metal inserts such as fasteners and magnets or other substrates such as structural reinforcements.

Two-shot injection molding eliminates the need for secondary processes such as welding and assembly. As such, piece prices tend to be lower for two-shot molded parts compared to multi-component single-shot assemblies. The tooling for two-shot, on the other hand, tends to be more complex and costly than single-shot. Therefore, two-shot injection molding is most cost-efficient for high-volume productions. Request a quote today to see if two-shot molding is the right solution for you.

We typically work with large customers such as automotive OEMs, Tier 1s, and Tier 2s. The majority of our accounts have volumes of at least 10,000 parts annually and have an annual buy over $100,000. If this sounds like you, we should connect.

Since 1995, Foam Creations is the North American manufacturer expert of Polyolefin injection foam molding products. Our team of engineers and designers supports our clients' projects, from concept to manufacturing, using the XL EXTRALIGHT® cross-linked foam molded technology.

More than a regular injection foam molding material, our XL EXTRALIGHT® compounds are inherently lightweight, flexible and ingenious plastic that have a high resistance to chemical in addition of being free of phthalates, heavy metals and latex. Our cross-linked foam technology makes our products 100% waterproof, very safe, soft and easy to clean. On top of it, our XL EXTRALIGHT® foam materials are available in various hardness and density. This is what, among other things, makes the XL EXTRALIGHT® materials greatly superior to other regular injection foam molding companies we can find in other parts of the world. Since 1995, more than 400 cross-linked foam products in the following industries have differentiate and create the renown of Foam Creations as a unique foam injection molding manufacturer:

Our expertise lies in two-shot overmolding and insert molding. In addition, we utilize in-house secondary processes and high levels of automation to lower labor costs and improve accuracy and lead times. Our team can determine the optimal processes for your part.

The two-shot injection molding process combines two different plastic resins in one machining cycle. To realize the full benefits of this process, you should choose two compatible materials that can form a molecular bond while simultaneously meeting the functional requirements of your part. Learn about the most common two-shot injection molding materials in our Two-Shot Design Guide, or contact us if you need help choosing compatible materials.

There are hundreds of materials suitable for two-shot injection molding and thousands of ways to adjust, blend, and fine-tune them. Our material experts can help you choose compatible materials that will form a molecular bond while simultaneously meeting the requirements of your part.

Two-shot injection molding is the ideal process for complex parts. As such, part design often requires a high level of refinement and sophistication. That’s why we’ve developed a Two Shot Design Guide. It provides the foundation you’ll need to start designing for the two-shot molding process.

Make informed decisions before full-scale production with our rapid prototyping capabilities. We evaluate the design and identify potential issues quickly and cost-effectively to speed up the product development process.

Our two-shot injection molded parts contribute to the success of major industrial sectors, including automotive, lawn & garden, heavy equipment, and consumer products. Explore the wide range of uses for our two-shot injection molding solutions.

Our two-shot injection molding company is located in Bad Axe, Michigan. You can drop us a note online, give us a call at 989-269-9791 or email us at plasticsales@geminigroup.net.

With decades of experience in two-shot injection molding, we’ve optimized our processes to drive cost out and maximize value for our customers. Our rapid prototyping, advanced molding techniques, and material expertise streamlines the production process from conception to production.

Two-shot design can deliver a competitive advantage far above other molding processes, especially for complex parts. Learn the benefits of the process and explore the special design requirements needed to make it work in this free guide created by engineers, for engineers.

Our two-shot injection molding company is ISO 14001:2004, ISO/TS 16949:2009, and WBENC certified. View our Certifications page.