Patent ID: 7731487

Claim:
A mold for forming an earplug that has a foam insertable portion and a foam handle portion comprising: a lower mold portion including a lower cavity; and an upper mold portion including an upper cavity; the lower and upper cavity configured to form the ear plug having the foam insertable portion and the foam handle portion; a nestable component that is more rigid than the foam of the earplug, the nestable component being insertable into the upper cavity of the upper mold, such that the nestable component becomes secured to the foam handle portion and is bondable with the foam during a rising of the foam, and removable from the mold upon a bonding with the foam, wherein the upper cavity includes at least one projection defining 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.