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.

See use cases where Fortify’s quick-turn injection molds were able to accelerate product development and gain quicker regulatory approval, among other benefits.

Plastics found under the hood and near the engine need to be tough, high-temperature resistant, and high-performance. Fortify is able to mold in these tough materials and complex geometries to create quick-turn automotive molds.

Fortify is the leader in molding high-performance plastics with 3D printed tooling. Now you can mold automotive prototypes in a range of plastics without going over budget or sacrificing quality.

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.

Quantities of high-performance automotive parts in the hundreds per year are often difficult to produce due to the need to justify tooling costs. Typically, this is addressed with costly CNC parts or FDM 3D printing which cannot create isotropic parts. Now you can get affordable low-volume quantities of the auto parts you need in 10 days or less.

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:

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.

Electrical vehicle manufacturers need to get functional prototypes in complex geometries to test their full car designs, but high costs and long lead times are barriers in automotive and EV prototyping. Don’t let high tooling costs slow down the prototyping process or add unnecessary costs to already expensive vehicles.