Case Study: FOAM‑iT achieves rapid on‑demand nozzle protection to meet COVID‑19 demand with Protolabs

Maker of Disinfectant Equipment Aids Pandemic Fight with On-Demand Manufacturing

FOAM‑iT, a 30‑year maker of chemical management and application equipment, faced a sudden surge in demand for its misting/disinfectant wands during the COVID‑19 pandemic. The fragile nozzle tips were being damaged in the field, and FOAM‑iT needed a protective, injection‑molded nozzle cover fast — far faster than the typical 3–5 month lead time for offshore tooling and parts.

FOAM‑iT worked with Protolabs’ on‑demand molding service and design analysis to finalize a two‑piece HDPE protector with an undercut snap and screw joint. After submitting CAD files on a Thursday, Protolabs delivered 250 prototype parts by Tuesday, parts that sold quickly and led to additional production orders; onshoring reduced delivery time from months to days, allowed retrofits for existing units, and—according to FOAM‑iT—paid for itself within the first week of sales.

FOAM-iT

Alex Vandertol

Product Development and Support Manager