Molded Foam | General Plastics
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Molded Foam


General Plastics fabricates and machines custom molded foam parts to customer specifications using high-density flexible and semi-flexible polyurethane LAST-A-FOAM® materials. Look to our unique foam formulations and proven built-to-print capabilities to satisfy your most demanding production requirements. Our high-capacity production facilities enable us to scale production to project needs – from a small, short-term run of specialty parts to an extensive, ongoing OEM parts program.

General Plastics Manufacturing Company is ideally qualified and equipped to manage all aspects of a molded foam part program. As your production partner, our seasoned estimators, CAD/CAM designers, procurement specialists, chemist and production staff will custom-develop your build-to-print program. Our team can support you with part and tool design, mold tooling manufacture, and production of parts through all phases to completion. When necessary, we will also custom-formulate appropriate foam systems to make just the part you need, with all the physical properties and other attributes you require.

Based on your specifications, we’ll recommend the optimal solution for density-to-part-weight control, void control, part consistency, surface quality and physical properties. Low scrap rates, competitive tooling costs and our collaborative approach make General Plastics a leader in custom molding services.

In addition, count on us for any accessory items needed to complete your assembly: metal brackets, clips, handles, other hardware, mounting fasteners, etc. We manufacture composite-laminate backing structures to provide support for foam parts if needed. To further streamline processes, we can also manage procurement and incorporate these items into your project if you desire.

Download Production Services Brochure

Our molded foam part capabilities and facilities include:

  • Part design
  • Tool design
  • Model-to-print and pattern-to print services
  • Mold tooling manufacture
  • Foam formulation with full QA documentation
  • Dedicated assembly room for engineered parts
  • Segregated, controlled-access ITAR assembly room for military parts

Custom molding, fabrication and assembly services include:

  • Pattern making
  • Mold design services
  • Part design
  • Prototype design
  • Tooling
  • CNC machining
  • Painting
  • Adhesive bonding
  • Prepreg, potting and resin-infusion processes


Aircraft manufacturers have trusted General Plastics’ top-flight parts for more than 40 years. We supply build-to-print flexible polyurethane foam molded parts to original equipment manufacturers and Tier 1 / Tier 2 companies.

Durable custom molded foam parts are manufactured from our flame-retardant, self-extinguishing, self-skinning flexible urethane foams. Our aircraft molded foam parts program spans flight deck and aircraft interior applications. Typical molded parts include:

Flight deck pads

  • Headliners
  • Assist handles
  • HUD covers
  • CD post pads
  • Glare-shield pads
  • Kick strips

Closeout seals

  • Bin-to-bin
  • Bin-to-monument
  • Galley and lavatories
  • Header seals
  • Mouse holes
  • Trash traps
  • Light blocks