XL EXTRALIGHT® technology

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.

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:

-Medical homecare equipment

-Spa pillows and accessories

-Seats (medical, kayak, indoor, etc.)

-Shoes and sandal soles

-Watersports accessories and safety devices

-Sport and equipment protective gear




Foam Creations is a global leader in the development of injection foam molding.

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.

XL EXTRALIGHT® material is non-toxic and offers numerous benefits.

Our foam materials are free of phthalates, heavy metals, and latex, making them very safe.

  • Lightweight and flexible
  • Chemical-resistant
  • Waterproof (closed-cell foam)
  • Complex and tridimensional geometry
  • Fire-resistant
  • High-quality surface finish (textures and logo)
  • Excellent mechanical strength
  • Available in many colors

Foam Creations specificities

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.

Foam Creations owns manufacturing plants in Canada and Mexico, which is a major advantage in terms of :

  • Short product development
  • North American manufacturer
  • Very short delivery timelines in the USA (just-on-time)
  • Very efficient customer service located in America