Abstract: A mold for forming a foam earplug including a lower mold portion including a lower cavity; and an upper mold portion including an upper cavity and a means for venting a gas during a rising of the foam, wherein the lower and upper mold portions are engageable so as to communicably engage the lower and upper cavities.

Abstract: A hearing device including a foam, a foam insertable portion, a component, and a foam handle portion, and a method of forming the same. The component is nestable with and bondable with the foam such that the component is at least partially within the foam insertable portion and the foam handle portion. The hearing protective device includes earplugs attached to a flexible cord, under-the-chin element, or headband. A method of making a hearing protective device including disposing a component into a mold, introducing a foam or foamable mixture into the mold, causing the foam to rise such that the component is nested within and bonded with the foam.