Innovative product design with foam injection molding starts here

Exclusive Molded Foam, Customized For Your Product Design And Specification

Are you developing an innovative new product and are looking to benefit from foam injection molding? Looking for a partner that can support your project from the initial design to manufacturing of foam molded product? Say hello to Foam Creations - leader in closed cell foam injection molding manufacturing.

Work With The #1 Eva Foam Manufacturer In North America

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The North American Leader In Foam Injection Molding Manufacturing

Foam Creations is the leading North American company that specializes in closed-cell foam injection molding for a wide array of products. We support both brand-name and niche manufacturers in creating one-of-a-kind products, using our unique EVA foam technology.

With decades of experience in foam injection molding and the mastermind behind the world-renowned CrocsTM footwear company and its foam injection molding clogs, Foam Creations has the proven track record and know-how to get any innovation project done—on time and according to spec.

Working On A Foam Design? Discover Our Wide Range Of Foam Manufacturing Solutions

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Why Use Our Foam Injection Molding?

Contrary to traditional EVA foam manufacturers, Foam Creations compounds a wide range of proprietary Polyolefin resins to manufacture any type of custom foam moldings. Our exclusive injection-molded XL EXTRALIGHT® is free of phthalates, heavy metals and latex, making it very safe, soft and easy to clean. What’s more: it’s soft, lightweight, 100% waterproof and chemical-resistant. XL EXTRALIGHT® can be used for a variety of different applications.

If you’re looking to go beyond conventional EVA foam products and take advantage of superior properties of XL EXTRALIGHT®’s premium injected molded foam, then you’ve come to the right place.

Work With One Of The Best Foam Manufacturers In North America

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Our Company's Advanced Foam Injection Molding Services - From A To Z

Thanks to our next-generation injection molded EVA foam and long-standing expertise in developing foam injection molding products, Foam Creations has carved an enviable niche in the industry for its market-driven mindset, unsurpassed quality, localized services, production capacity and unprecedented delivery speed.

At Foam Creations, we don’t “just” supply foam injection molding services. We offer end-to-end product development services that leverage the stellar performance of our XL EXTRALIGHT® foam to manufacture ahead-of-the-curve products that make significant impact in their respective markets.

Choose Flexible Foam Solutions With Foam Creations - Leading  Foam Supplier

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With Foam Creations, Seeing Is Believing.

For over 20 years, Foam Creations has been providing foam injection molding services that cater to a wide range of industries, including the medical, protective gear, water sport accessory, seating, spa and footwear sectors.

Our Commitment - Provide Foam Materials Made With The Best Technology And Tools

No matter what type of consumer goods or B2B project you have, we can help you develop a custom product using our injection molded XL EXTRALIGHT® foam.

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Our Company's Foam Fabrication Services

Foam Material Production

Foam Creations helps you choose the best EXTRALIGHT® foam for your custom molding project. Our superior Polyolefin-based material is phthalate, heavy metal, and latex-free, ensuring safety. It's 100% waterproof, soft, and easy to clean. Our strength lies in EXTRALIGHT® custom foam molding technology.

Foam Product Design

With our in-house design department, Foam Creations collaborates closely with clients to enhance the design of their molded foam products. With 20 years of contributions to revolutionary foam products (like Crocs, balls, pillows), we've become a global expert in XL EXTRALIGHT® custom foam molding. 


After product design, we recommend crafting a foam prototype—a crucial step to validate design functionality before moving on to foam manufacturing in the development process.

Foam Molds Manufacturing

Foam Creations oversees the production of molds for foam injection molding, utilized in our Canadian and Mexican manufacturing plants. Our team manages this crucial step in developing your molded foam products.

Custom Foam Products Manufacturing

Foam Creations produces EVA foam products, including XL EXTRALIGHT®, in Canadian and Mexican manufacturing plants for fast development, high quality, and on-time delivery while keeping transportation costs low. As a foam fabricator, top priority is maintaining superior quality and flawless control over clients' specifications.

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What Industries Work With Foam Creations For Their Foam Manufacturing Needs?

Foam Creations, a leading foam fabrication services company, caters to a wide range of industries across North America. Our commitment to delivering flexible foam solutions extends to markets such as healthcare, sports, and more. With vast experience in foam injection technology, our company utilizes state-of-the-art equipment to meet diverse specifications and provide custom foam molding solutions for an extensive range of applications.

What Types Of Foam Products Can Be Done Using EVA Or Polyolefin?

Foam Medical Devices

Foam Creations excels in using EVA and polyolefin foam for the production of medical devices. Our custom foam molding ensures the creation of ergonomic and durable components for surgical equipment, rehabilitation aids, and other healthcare solutions.

Foam Sporting Goods

From protective gear to buoyant components, Foam Creations leverages these foam materials to enhance the comfort, safety, and functionality of sporting equipment.

Foam Soles and Shoes

Foam Creations is at the forefront of incorporating EVA and polyolefin foam into the footwear industry. Our custom foam products, including shoe soles, provide exceptional cushioning, flexibility, and durability, catering to the unique needs of both casual and athletic footwear.

Custom Foam Products

Unleash creativity with Foam Creations' custom foam molding services using EVA and polyolefin foam. Our expertise in foam fabrication ensures the realization of custom foam products tailored to your specific requirements

What Other Types Of Foam Can Be Manufactured?

  • Polyurethane Foam: Polyurethane Foam is a versatile material ideal for applications such as automotive components, furniture, and insulation.
  • Polyethylene Foam: Polyethylene Foam can be used in packaging, cushioning, and insulation. Custom foam products using polyethylene foam can offer good protection and versatility.
  • Polystyrene Foam: Polystyrene Foam is known for its lightweight and thermal insulation properties. This foam type is commonly used in packaging, construction, and various consumer goods
  • Acoustic Foams: Specialized acoustic foams are ideal for soundproofing applications in theaters, studios, and commercial spaces thanks to good sound absorption and insulation.
  • Cellular Foam: Cellular Foam is used in diverse industries, including automotive, aerospace, and electronics. 
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