Breaking the Mold - Foam Molders gets the job done through various techniques.

Since 1971, Foam Molders & Specialties has offered engineering, molding and fabrication of flexible and rigid foam. In the early years, FMS qualified to various military and aircraft makers specifications (BMS 8-350, DMS 2451 and FAR 52.853) for molded and fabricated polyurethanes. Having qualified systems to Hughes, Douglas and Boeing, as well as AMS and Mil-Spec foams, (Mil- 21929 and Mil-PRF-83671) enabled them to participate then and now in many aerospace, aircraft and highly specialized military and commercial programs.

FABRICATION:
With technology playing a major part in production these days, engineers at Foam Molders & Specialties adhere to the old saying, "If it ain't broke don't fix it," but at FMS they are always finding ways for continual improvement that will help increase production, streamline processes and reduce cost in manufacturing. The artisan approach "a person manually skilled in making a particular product or craftsmanship" is alive and well at FMS.

FMS has produced a fairly complex cushioned seat for over 20 years, making continual improvements to the part, while not compromising the quality and attention to detail. They see this part being produced right next to a "state of the art" computer aided hot wire cutting machine. Knowing which process best to use is key in the development and production of parts today.

FMS takes three very different types of foam, slit and cut to size, creating five independent pieces. They utilize hot wire cutting by hand for some of the pieces (which produces channels needed for cooling). Then, the five pieces are bonded together and finally trimmed, maintaining a fairly complex contour while meeting all other dimension tolerances.

VACUUM FORMING/ THERMOFORMING:
FMS offers vacuum and pressure forming, with the ability to form thermoplastic sheets into 3D shapes. When sharp, precise detail is desired, vacuum formed parts make an attractive alternative to other molding processes. FMS can handle sizes up to 144 in. x 120 in. x .50 in. thick, while achieving tolerances of 0.030 in. or less. A Class "A" textured pressure formed finish generally looks better or compares equally with a textured injection molded part.

Vacuum formed pieces are everywhere. FMS supplies various interior parts such as air duct covers, foot rests, throttle housing covers, and a center console requiring several assemblies. In addition, they supply various covers for electrical applications, recessed telephone boxes, control boxes and large items that use the fiberglass / epoxy molds.

One of the keys to their success is the ability to handle those various sub-assemblies that can be associated with the final part being produced. By staying current on aerospace manufacturing processes and materials, the staff at FMS is able to work with strong, lightweight and heat-resistant engineered plastics, including GE Ultem (polyetherimide or PEI).

SPECIALITY MOLDING (R.I.M.):
Reaction Injection Molding is the process of taking two liquid components (a polymer resin blend and a modified diisocyanate), and blending them using a high pressure mixing system and injected into a closed mold at low pressure. The reaction yields a polymer that pricisely takes on the details of the mold cavity.

The chemicals used can be adjusted for pliability, control, density and texture. The overall look can be altered by the characteristics of the mold. R.I.M. saves time, with shorter lead times and a reduction in the cost of the mold compared to that of injection molding.

One of FMS' major markets is fuel floats for both military and commercial aircraft. Floats are molded and pressure tested in jet fuels under strict quality control specifications, which include crush or weight gain (absorbed flight fuel) to less than 0.5 grams and x-ray verification.

COMPOSITE MANUFACTURING:
FMS processes composites out of fiberglass and carbon fiber, impregnated with high temperature epoxy and phenolics. They are able to produce their own composite molds and tools for vacuum forming, molding and composite layout.