A process for manufacturing an expandable member such as a tissue expander or like product for use in plastic, reconstructive, and other surgery. A compression mold with a desired initial, predetermined geometrical configuration shape is filled partially with a layer of unvulcanized flexible material, such as silicone, a thin layer of Teflon or like non-stick substance, and followed by another layer of unvulcanized material. The Teflon is "sandwiched" between the unvulcanized material and cured in an oven or by other suitable means. The non-stick material provides a separation region for subsequent expansion by injection of suitable material, air, fluid, etc. The non-stick material can be shaped to provide expansion only in the desired regions. Single, multiple, or overlapped layers of non-stick material may be employed to manufacture a variety of expandable products in the fields of medicine, surgery, consumer and industrial applications.