Foam molding service

Bra Cup, Nursing Pad, Swimsuit Insert, Bridal foam pads, ...




Moulage Ranger has been specializing in the thermoforming of polyurethane foam (bra cups, shorts, etc.) for over 40 years.

Molding foam (or Thermoforming ) is a process that imparts a precise form to a material by applying heat in order to congeal it to that appearance. Although it is used for many materials, we principally specialize in molding textile products. The lamination and molding processes are favoured to impose a shape on women’s swimsuits (triangle insert foam cup), dresses, bras, bras pads, foam cups, cycling shorts(light padding for your seat), helmet interiors, masks, breast-feeding cushions, and much more.

Moulage Ranger - Bonnet soutien-gorge -fabriquant

“More than
40 years in the textile industry “

At  Ranger Molding (a division of Ranger Group), we have been executing thermoforming for over 40 years already, our expertise and know-how are well established. We are able to rapidly respond to your needs because of this expertise. Also, we possess a large number of standard molds, among others, for bras cups (foam cups and swimwear cup inserts) as well as for different products necessitating thermoforming, for example in the field of lady’s lingerie. The scope of our inventory saves you the cost of acquiring a mold. It is also possible to create molds specifically for your projects. Our work force specialized in sewing, permits us to entirely or partially fulfill your product to increase your productivity. Please ask us for samples, you will be conquered by the quality of the product!


I want to make a new bra, what are the steps?

It’s best to contact us before creating your new design. We can suggest standard cup that will save you the cost of developing a specific cup for your application.

Although the shape of the cup is standard, we can vary the cut to create a unique model. The development of a single cut is much more affordable (usually under $ 300)

What is the difference between molded foam cups (bra, swimsuit, dress,…)?

Bandeau Cup

This model is characterized by the fact that the two cups are joined in one piece. This cup is mainly used for dresses and sport bra  (0030)

Insert Foam Cup

These models are often triangular shaped and is used for swimsuits. It fits between 2 pieces of material. Sometimes they are sewn into the swimsuit.

Teardroop Foam Cup

This shape is ideal for those not looking for extra lift, but to simply give the garment a contoured look. Teardrops are the best fit for halter style tops, placing the pointed end at the top. can be easily sewn into your wedding gown.

Push-up Foam Cup

The pushup cup is most popular. It has extra volume at the bottom of the cup in order to push the breast up and make it appear about 1-2 cup sizes larger. It is slightly tapered at both ends of the cup.


This all-purpose cup is made for creating a smooth, defined shape. Women who need a little extra room at the top of the cup, without sacrificing any lift should wear a round cup. This cup is also use for nursing pad.


This style is the most popular for bra making. It contains an integrated strap for ease of manufacture.  CP001, CP050UP

Bubble Molding ( Bullet Molding) 

Round-shaped molding is generally used on fabrics. The tissue is pushed into a cavity and heated for 30 to 60 seconds to create a permanent shape.

All materials made from synthetic fibers are suitable for molding. Nonwoven fabrics and spacer fabrics are suitable for this purpose.

This product is mainly used for dresses, swimsuits and bralettes.


Check all our Bra Cups.

What cups are used for swimsuits?

Most of the time, swimsuits use inserted cups (see our inserted products). They are made of thermoformed polyurethane foams with low water absorption, which is very popular

What foam thickness should I use?

For swimwear, we normally use thin foams to reduce water absorption. A thickness of 3/16 is recommended.

For the bra, it is mainly ½ and 3/8 ” thick.

For wedding cup or dress , we use ½ to 1 “thicknesses depending on the desired firmness. Do not be afraid, even under a 1 ” foam, once compacted, the cup will have a maximum of 3/16 thick in the center and 0.06 ” on the periphery for easy sewing.

Can we have cups without foam?

Yes. We have products without any foam. To do this, we have to laminate 2 fabrics together. Then we can mold it and the material will keep the shape and depth.

What cup is used for bralettes?

The bralette don’t normally use a bra cup, but rather a fabric forming (also bubble molding or bullet molding). Circular shape is molded into the fabric at the desired depth. This technique is also used for the manufacture of swimsuits.

Although bralettes normally do not use bra cups, some designers prefer to incorporate them. So we have an appropriate model. Bralette Cup (7073B, BAL200).

What material can be used to mold bra cups?

100% cotton , PolyCotton/Spandex ,100% Polyester simplex fabric

How are cup cover are made?

The covers are made with the same mold as the cups. This makes sure you have the same shape and saves time in sewing.

Do you only mold your fabric or can we supply ours?

We have standard colors, but you can supply your fabric without any problem.

How many bra cup mold do you have?

We have more than  100 molds.

Ensemble de moule pour les bonnets de soustien-gorge

Do you sell more expensive than imports from China?

Yes, but about 20%. This is due to the quality  and  thickness of the foam we use and the salary conditions in the North American. By law, we have to use a foam that meets the severe environmental standard. What some countries do not have to respect.

Are your products really made in Canada?

Yes, 100% of our products are molded in our plant in the province of Granby, Quebec, Canada near the state of Vermont and NY. Foam and material are manufactured within 100km of our factory.

Do you have the ability to produce high volume?

Yes, we have more than 40 machines ready to produce your bra cups.

What are your minimum quantities to order?

48 pairs per style per size, per color

What bra foam cup size are you able to do?

We carry a large range of sizes, from 30 to 50. All our cups are all formed, so seamless.

Can you laminate PUL (waterproof polyurethane laminate fabric)?

Yes, we are able to laminate the PUL on the foam. On the other hand, some produce it’s more difficult to stick. You can experiment with your product to ensure good adhesion. We use PUL products especially with nursing pads.

Do you laminate the foam in your factory?

Yes, we have equipment to laminate the material. We use an approved liquid glue process for products in contact with the skin. We can laminate 2 fabrics together, fabric-foam- fabric, fabric -felt- fabric, and more. See Laminate page



    780 rue Georges-Cros,

    Granby, Québec, Canada J2J 1N2


    Request a Sample

      Number of employees

      Select CUPS (required)
      Swimsuit InsertStraplessnursing padsPush-Up cups

      I agree to be contact by a representative of Ranger Molding ( by phone or email).