With such a versatile product having so many useful properties, many customers ask us about the method of how to mold foam? The product starts off as polystyrene beads which expand when treated with heat and steam. Blowing agents include pentane and carbon dioxide – both free from CFCs. The expansion process also creates millions of air pockets giving lightness and strength. It’s also during this expansion process, that our versatile material is molded into the huge range of shapes and sizes available from 100 locations nationwide.