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Memory Foam

We at GB Foam Direct are proud to offer our customers foam products made from a variety of grades and types. Along with more than 40 years of experience, we utilise advanced cutting machinery to bring you foam in all manner of shapes and sizes. One of the most popular foam types we work with was originally developed by NASA’s Ames Research Center. Nowadays, many of us choose to sleep on top of it for maximum comfort. We are of course, referring to memory foam.

Below you will find just a few of the products GB Foam Direct offers. This includes pillows, wheelchair cushions, foam crumb and upholstery sheets. You can also look at our range of mattresses.

When we think of memory foam, most of us will tend to attribute it to mattresses. It’s true that memory foam is one of the most popular and effective ways to stay comfortable at night. However, this unique material has a vast array of uses as well as a surprising history.

What is Memory Foam?

Memory foam is a polyurethane foam type, sometimes referred to as viscoelastic foam. Memory foam has the ability to slowly return to its original shape once pressure is applied. This means that it has a high level of viscosity (hence the name viscoelastic foam). Because of this, it is regarded as a low-resilience polyurethane material (LRPu).

Who Created Memory Foam?

You may be surprised to learn that NASA played a part in the development of memory foam, back in 1966. NASA needed to develop a means to improve the safety of their aircraft cushions for pilots and passengers. As such, they contracted their Ames Research Center to develop such a material. The resulting product was aptly named “slow spring back foam”.

Slow spring back foam may well be an informative name, but it doesn’t have the same ring to it as memory foam does. That name would catch on much later when the material became available for commercial use.

How is Memory Foam Made?

Like all PU foams, memory foam is primarily made up of polyurethane. Polyurethanes are created by reacting together diisocyanates and polyols. When mixed together, these two chemical compounds begin to rise and foam, similar to the way a baking cake would rise.

During the manufacturing process, polyurethane foams can be altered in specific ways to create certain traits. For example, in the case of memory foam, gas is pumped through it during production. This gives memory foam an open cellular structure which allows air to flow freely through it. The result is a unique foam type which has a high viscosity. This means that it can freely mould to a unique shape when pressure is applied to it, making it the ideal product for comfort purposes.

The Uses of Memory Foam

You already know that memory foam is great for sleeping on, but you can also find it in –

  • Footwear.
  • Pillows.
  • Wheelchair Seat Cushions.
  • Bath Mats.
  • Headphones.
  • Sports Safety Equipment.
  • Hospital Beds.
  • Bike Seats.
  • Military Wear.

This incredible foam has plenty of uses, some of which you may not have ever considered. The uses mentioned above are just a few of the situations where we can benefit from it.

Memory Foam Cut to Size

Here at GB Foam, we specialise in foam cut to size. This means that we can cut a variety of foam grades to shape and size for the benefit of our customers. Whether you require new foam sofa cushions or a bespoke mattress made for your campervan, we can help.

Every day, we transform regular blocks of memory foam into unique products used for a wide variety of purposes. Whether it be memory foam mattresses, toppers, pillows, wheelchair cushions or upholstery sheets, this is a foam type loved and used by many of our customers. If you need memory foam cut to size, remember to choose GB Foam Direct.

Why Choose GB Foam For Your Foam Cut To Size?

Our factory is equipped with the latest CNC cutting technology and throughout the years we have employed the most talented freehand foam cutters in the industry. Many members of the team have worked for the company for several decades and their attention to detail and quality control is something that only comes with years of knowledge and experience.

We have many customers who started with us in 1976 and are still working with us today, which we like to think reflects on our vision to be the most dynamic foam converter in our industry. For us no job is too big or too small. We offer the same level of service and delivery whether you are a retail customer ordering one piece of foam from home, or a large manufacturer ordering daily.

GB Foam Celebrating 40 Years in Business
40 Years In BUsiness

GB Foam have been offering foam cut to size from our factory since 1976.

Foam Made In The UK
Hand Made In THe UK

We employ the most talented freehand foam cutters in the industry.

Foam Made In The UK
ISO 9001 Quality

Our team work to the ISO 9001 quality standards to guarantee only the best

Super Fast Foam Delivery
Super Fast Delivery

All orders placed before 11:30am will be despatched for next working day delivery

5 Year Foam Guarantee
5 Year Guarantee

Our foam comes with a 5 year guarantee against faults in manufacture.

Flame Retardant Foam
Flame Retardant

Our entire range of foam exceed UK safety and flammability standards.

How We Cut Foam

GB Foam Direct Factory - Foam Cut To Size

Thanks to the use of advanced cutting machinery, as well as our talented freehand foam cutters, we can create the foam products you need. You may not always see it, but many of us benefit from the use of foam every single day. Whether we’re using foam for comfort or to wash our dishes; look around and chances are something near you will contain it.

Foam is an extremely useful and versatile material, one that has a multitude of uses. It can be manipulated and cut to practically any shape or size. This makes it the ideal product for use in a multitude of situations. When our customers require the benefits that foam offers, we create them products which are fit for purpose.

Our Foam Cutting Machinery

We’ve invested in a wide range of foam cutting machinery. Some of our products are created by hand, whilst more intricate pieces can be made enabled by computer technology. We’ve been converting foam for more than 40 years now. Technology has of course changed, but we’ve always kept up to date. Nowadays, the most intricate foam products can be created in no time at all, by harnessing the use of advanced foam cutting technology.

Computer Enabled Foam Cutting

Thanks to advances in the field of cutting technology, it’s now easier than ever before to create bespoke foam products. We have several CNC (Computer Numerical Control) cutting machines here at GB Foam. These machines enable us to create intricate and complex foam designs aided using computer technology.

Items such as case inserts are a great example of the benefits this type of technology offers. Items contained within cases will tend to vary in shape and size. If these items are of great value or importance, you’ll naturally want to protect them. You’ll likely have great difficulty finding a foam case insert made to cater to your specific requirements. As such, you’ll need a bespoke product created. This where our services come in.

Our CNC machines can accurately read CAD (computer-aided design) files. If we were to create a CAD file catering to your specific requirements, our CNC machines could precisely replicate it in foam. This process can then be repeated multiple times to create an abundance of bespoke foam tray inserts. These could then go on to be used in retail products, on production lines or within a toolbox to name a few examples.

Manual Foam Cutting

We don’t just rely on computers to carry out our work. We employ some of the most talented freehand foam cutters the industry has to offer. A Band Knife and Tilt Knife, for example, require a talented individual to operate them. The Band Knife allows us to create foam sheets which upholsters use to build and refurbish furniture. Meanwhile, the tilt knife allows us to precisely cut foam blocks at specific angles. This can be utilised in the production of certain foam cushions and mattresses for example.

Mattress Rolling

Did you know that our mattresses are delivered to your door compressed and rolled? Due to the material structure of some foam types, it is possible to compress the air out of the cells. This leads to the foam becoming much smaller than it once was. We compress our mattresses using heavy rollers. They are then rolled and vacuum sealed, meaning that they won’t return to their original size until the seal is broken.

The method of mattress rolling makes it much easier for us and yourself to transport a mattress to any desired destination. Once the mattress is re-exposed to air, the cells will once again fill. This allows the foam to return to its original size. It usually takes around 3 hours for it to fully return to an original shape. It’s also important to note that this method doesn’t in any way damage the mattresses we make. Foam is designed to be compressed and is a very robust material.

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