Custom Molded EVA Foam Parts & Compression Molding
Direct OEM manufacturer of custom molded EVA foam parts and compression molded foam components. In-house CNC aluminum tooling, custom densities (35–250 kg/m³), and tight B2B tolerances.
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Precision Custom Molded EVA Foam Components
When 2D flat die-cutting and CNC milling cannot achieve the complex contours, seamless curves, and ergonomic geometries your design demands, custom molded EVA foam parts deliver the ideal solution.
Damao Tech manufactures precision thermo-compression molded EVA foam components for protective sports gear, medical orthotics, automotive sealing, luxury packaging liners, and ergonomic tool grips. We operate an integrated facility featuring in-house CNC tool machining, polymer compounding, high-tonnage hydraulic presses, and automated perimeter trimming.
For flat raw material stock or sheets, visit our custom EVA foam sheet manufacturing page or our primary EVA foam materials overview.
The Compression Molding Process
- Pre-Form Blank Preparation: Precision-cut blanks with exact volumetric mass are die-cut from calibrated EVA foam sheets.
- Thermal Activation: Blanks are heated in temperature-controlled infrared ovens to the polymer softening point (120°C–160°C).
- Hydraulic Compression: The softened foam is pressed in CNC-machined aluminum cavities under 50 to 200 tons of hydraulic pressure.
- Rapid Cold-Setting: Circulating chilled water freezes the molecular matrix inside the mold, locking in intricate details, embossed logos, and deep contours while preventing post-demold shrinkage.
- Flash Trimming & Finishing: Automated trim dies remove perimeter flash, followed by adhesive lamination (PSA) or textile heat-bonding as required.
Key Applications for Molded EVA Foam
- Protective Sports & Safety Gear: Helmet comfort liners, articulated knee and shin protectors, shoulder pads, and chest impact plates.
- Medical & Orthopedic Supports: Anatomical braces, orthotic arch supports, wheelchair positioning pads, and respiratory mask cushions.
- Ergonomic Grips & Bumpers: Tool handles, sporting equipment grips, steering dampening blocks, and vibration isolators.
- Technical Equipment Packaging: Contoured carrying case liners, drone cradles, optical instrument housings, and high-end consumer electronics cases.
Density & Hardness Selection Guide
| Application Category | Density (kg/m³) | Shore C Hardness | Key Physical Function |
|---|---|---|---|
| Soft Cushioning & Comfort | 35 – 55 kg/m³ | 20 – 35 Shore C | Lightweight, skin-friendly, high flexibility |
| Damping & Ergonomics | 60 – 90 kg/m³ | 40 – 50 Shore C | Balanced resilience, impact dispersion |
| Structural Protection | 100 – 160 kg/m³ | 50 – 65 Shore C | High structural memory, tear and puncture resistance |
| Heavy Load & Machinery | 180 – 250+ kg/m³ | 65 – 80 Shore C | Rigid, load-bearing, low creep deformation |
Request a Tooling Review & Quotation
To start your custom EVA foam molding project, send your 3D CAD models (.STEP, .STP, or .IGES) along with 2D drawings detailing critical tolerances.
- For engineering design guidelines, read our Custom Molded EVA Foam Parts Sourcing Guide.
- Contact our engineering team today to schedule a DFM (Design for Manufacturability) review and receive a prototype quotation.
Technical Specs
Core technical parameters and performance indicators for precision EVA foam production.
- Molding Method Thermo-Compression Molding & Cold Setting
- Density Range 35 – 250 kg/m³
- Hardness Range 20 – 80 Shore C
- Tooling Material CNC-Machined Aircraft Aluminum (6061 / 7075)
- Wall Thickness 2 – 40 mm (Contoured & Variable Profiles)
- Dimensional Tolerances ± 0.5 mm to ± 1.0 mm
- Secondary Operations Die-Trimming, PSA Lamination, Fabric Bonding, Laser Etch
- Compliance RoHS, REACH, EN-71, Non-Toxic & Odor-Free