Abstract: An apparatus and associated method are disclosed for making a polymer foam cushioning element. The method comprises advancing a pair of sheets of plastic film material in parallel face-to-face relationship; injecting foam precursors between the advancing plastic sheets; sealing the sheets together to form a plastic bag containing the foam precursors; forming the bag into the shape of a panel; and thereafter maintaining the bag in the panel shape until the foam precursors have substantially finished expanding into foam to thereby form a foam cushion panel.