A fluid-filled chamber may include an outer barrier formed from a polymer material and a foam tensile member located within the outer barrier. In manufacturing the fluid-filled chamber, a mold may be contoured to substantially equalize compressive forces between the outer barrier and various portions of the tensile member, thereby providing substantially uniform bonding between the outer barrier and the tensile member. Surfaces of the tensile member may also be contoured to substantially equalize compressive forces. In some configurations, the outer barrier and tensile member may be formed from thermoplastic polymer materials that form a direct bond between the outer barrier and surfaces of tensile member.