Facial interfaces for head-mounted displays and related systems and methods

A method comprising:

• positioning a mold insert in a mold that has an internal cavity defining a shape of a facial interface for a head-mounted display;
• securing at least two pegs into the mold insert by attaching heads of the at least two pegs to the mold insert;
• injecting a liquid material into the mold to surround at least a base of the mold insert and to surround respective bases of the at least two pegs with the liquid material;
• curing the liquid material to form a foam body with an undercut region defined by the mold insert;
• removing the foam body from the mold;
• and
• decoupling the mold insert from the foam body.