The Zome kids dumbbells were made with a moldable high-density polyurethane foam. Two 3D-printed  interlocking molds were used, along with polyurethane dye and a two-part pourable foam.

Process

The goal was to find a lightweight, soft, and durable material to cushion the inner iron weight

A two- pound iron weight was to be co-molded in between the two foam outer layers

Foam is dyed and mixed

1

First half is poured into mold

2

First half is removed and trimmed

3

Iron weight is inserted into first half

4

First half is put into second mold and second half is poured

5

Prototypes