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.

Abstract: A high pressure method of molding polyurethane articles is described. A polyurethane material is formed from a cross-linkable polymer comprising the reaction product of a polyol and polyisocyanate, said polymer containing a high activation temperature catalyst and a high surface area filler. The material is processed to a gum state suitable for high pressure molding. The material and process are particularly suitable for forming small, intricately shaped articles. Such articles are also described.