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.
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
First half is poured into mold
First half is removed and trimmed
Iron weight is inserted into first half
First half is put into second mold and second half is poured