Foam Cutting / Foam Fabrication

On the Cutting Edge of Foam Technology

Foam Contour Cutting – Computer-assisted foam cutting method used to cut polyurethane foam into custom, complex shapes.

Convoluted Foam – Method of cutting a single piece of compressed foam into two identical shapes to minimize wasted foam material. Convoluted foam is often referred to as egg crate foam.

Foam Die Cutting – Uses stamping equipment, such as mechanical presses, for consistent results. Die foam cutting is used to produce foam gaskets, foam insulation, and die cut foam packaging.

CNC Foam Cutting – Polyurethane foam (PU) is inserted into either a horizontal or vertical CNC machine and cut along a pre-determined path. CNC foam cutters provide increased accuracy when fabricating intricate foam designs.

Automated Gluing – Adhesive is automatically applied to contour cut foam for bonding with similarly shaped parts. Automated gluing is typically used for large production runs.

Foam Heat Bonding – A post treatment foam fabrication method which requires foam to be heated, then applied to foam material.

Hot Melt Laminating – Involves heating a single side of polyurethane foam sheets to near melting point, then bonding the heated side to one or more foam sheets to form a composite. Foam heat melt lamination eliminates the need for adhesives. Laminating is a type of adhesive.

Pressure Sensitive Adhesive – Foam adhesives designed to be applied at room temperature. Pressure sensitive adhesive allows for easy on-site or in-house applications of foam to different substrates.

Foam Sewing – Includes fabric pouches, bags, and covers generally used for automotive dunnage.

Sonic Welding – High frequency acoustic vibrations create a solid state bond without the use of adhesives or soldering. Sonic welding is frequently used to bond plastic corrugated as used in partition sets & dividers.

Waterjet Cutting – Foam has multiple watercut foam cutters capable of straight cuts and complex angles.

Contact Foamworks for additional information on foam fabrication, or call us at 888.309.FOAM (3626) to begin production on foam designs cut precisely to your specifications.