Best Seller · 200+ Shapes Available

Molded Foam Bra Cups

$0.15 - $2.50 / pair (FOB Dongguan)

High-density polyurethane molded foam cups designed for bras, swimwear, lingerie, and sportswear. Manufactured with precision heat molding technology for consistent shape retention and long-lasting comfort. Choose from 200+ existing molds or custom design your own shape.

MOQ:1,000 pairs (custom mold: 5,000 pairs)
Size Range:AA to G cup (custom available)
Material:PU foam + fabric lamination
Foam Density:18D - 40D options
Lead Time:15 - 25 days
Certification:OEKO-TEX, SGS, CE, ISO9001

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Product Overview

Our molded foam bra cups are crafted using high-quality polyurethane foam and advanced heat-molding technology. Each cup is precision-molded to ensure consistent shape, symmetry, and durability wash after wash.

We offer both push-up and contour styles in a wide range of shapes: demi-cup, full-cup, plunge, balconette, strapless, and sport styles. All cups can be laminated with your choice of fabric for the perfect finish.

Key Features

Premium polyurethane foam with excellent shape retention
200+ existing mold shapes to choose from
Custom mold design service available (free if MOQ ≥5000 pairs)
Multiple fabric lamination options (nylon, polyester, cotton, bamboo)
Available with or without underwire channels
Washable, non-toxic, hypoallergenic materials
OEKO-TEX Standard 100 compliant

Fabric Lamination Options

Nylon Tricot: Smooth, durable, most popular choice
Polyester Jersey: Soft, stretchy, economical
Cotton Blend: Breathable, natural feel
Bamboo Fiber: Eco-friendly, antibacterial
Satin & Lace: Premium finish for luxury lingerie
Customer-provided fabric: Send us your fabric

Cup Shapes Available

Demi cup / Half cup
Full coverage cup
Plunge / Deep V cup
Balconette / Balcony
Strapless / Multi-way
Sports bra cups (high impact)
Swimwear cups (waterproof)
Bralette & triangle cups

Technical Specifications

Physical Properties

Foam type: Polyurethane (PU) flexible foam
Density range: 18D, 22D, 25D, 30D, 35D, 40D
Foam thickness: 8mm - 40mm (custom available)
Cup size range: AA, A, B, C, D, DD, E, F, G
Bottom band size: 30 - 46 (US/UK sizing)
Shape retention: >85% after 50 washes
Color: White, black, beige, nude, custom dye

Performance Testing

Tensile strength: ≥ 120 KPa
Elongation at break: ≥ 150%
Compression set: ≤ 8%
Shrinkage (after wash): ≤ 3%
Color fastness: Grade 4+ (AATCC)
Formaldehyde: < 75ppm (baby grade <20ppm)
pH value: 4.0 - 7.5 (skin-safe)

Quality Control Process

Every batch of foam cups undergoes rigorous quality inspection at multiple stages of production:

Incoming Inspection (IQC)

Foam density & hardness verification
Fabric weight & composition testing
Color matching with approved sample
Raw material traceability check

In-Process Inspection (IPQC)

Mold temperature & pressure monitoring
Cup shape & symmetry measurement
Lamination bond strength test
Edge trimming quality check

Final Inspection (FQC)

100% visual inspection for defects
Left/right cup matching (size & shape)
Random wash test per batch
Packaging & labeling verification

Testing Standards

OEKO-TEX Standard 100 Class II
SGS testing report available
ISO 9001:2015 quality system
Customer-specific QC protocols welcome

Product Applications

Our foam cups are used across a wide range of apparel industries

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Bras & Lingerie

Everyday bras, push-up, minimizer, bralettes, and luxury lingerie

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Swimwear

Water-resistant foam cups for bikinis, one-piece, and tankinis

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Sportswear

High-impact sports bras, athletic tops, and fitness apparel

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Fashion Apparel

Dress cups, camisoles, wedding dresses, and formal wear

Production Process

From raw material to finished product in 5 carefully controlled steps

Material Prep

Foam sheet cutting + fabric lamination with eco-friendly adhesive

Heat Molding

Precision hot press molding at controlled temperature and pressure

Edge Trimming

CNC trimming for clean, smooth edges with perfect symmetry

Quality Check

100% inspection of size, shape, and visual defects

Packaging

Pair matching + poly bag + carton with custom labeling