Custom Fabricated EPS Insulation and Support for Air ExchangersWhen a manufacturer of HVAC equipment was suddenly confronted with the reality that they could no longer procure required parts from their current expanded polystyrene molder, they had a real dilemma. Fortunately, the manufacturer turned to Robin II, a custom molder and fabricator of EPS. Robin II examined the customer’s component drawings and existing tooling and was able to retrofit the mold, produce samples, and—once approved—begin production of the components for the heat exchangers’ molded foam interior. Since most of the tooling was made from cast aluminum, the job required a large precision mold which was CNC machined and had little draft or taper. The mold was extremely complex, with multiple cavities and “windows” on nearly every surface, which required hand extraction at the end of each cycle. Made from 4 pcf density virgin EPS, the final dimensions were 24.5″ x 22.5″ x 18.5″. Built to customer specifications and customer-supplied drawings and tooling, the complicated foam interiors undergo 100 percent visual inspection prior to delivery.

To learn more about these extensive capabilities see the table below or contact Robin II with your requirements directly.

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Product Description

Used for Interior insulation and structural support in large Air Exchangers

Capabilities Applied/Processes


  • Designed
  • Molded
Overall Part Dimensions

Assembled components are 24.5” x 22.5” x 18.5”.

  • There are fourteen additional molded and fabricated parts that complete the assembly.
Material Used

4 pcf virgin EPS

Material Finish

Color White

In process testing/inspection performed

100 % visual inspection

Industry for Use

HVAC, commercial and industrial

Standards Met

Customer Specifications

  • Customer-supplied drawing and tooling