Thanks for all the comments and ideas. There really is not much left to do. We have a new way of forming theses bumpers and because of it I really did not need to do as much work as I did. We now only have to form half of the bumper which makes building one a lot faster and a lot cheaper.
As for what is next; The foam will be measured by laser into a CAD drawing. Then a new, stronger mold will be machined. The new mold can then be reused as many times as we need. Next the mold is covered and using Pressure Vacuum we end up with the final product.
Doing something like this is not cheap but it's worth it to have something that no one else has.
It is great to see people interested in this kind of work. If you have any questions or want to learn how it is done feel free to ask and I will do my best to answer any questions you have.
- J-R
Mettetech Automotive