Memory Foam

When we think of memory foam, most of us will tend to attribute it to mattresses. This foam type is one of the most popular and effective materials for providing support and comfort, however, it also has an array of other uses as well as a surprising history.

What is Memory Foam?

Memory foam is a polyurethane foam type, sometimes referred to as viscoelastic foam. It can be manipulated into various forms and slowly returns to its original shape once any applied pressure is eased. 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 developed memory foam back in 1966. NASA required a means to improve the safety of its aircraft cushions for pilots and passengers. As such, they contracted their Ames Research Center to develop a material to provide this. 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 the 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 this 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 foam into unique products used for a wide variety of purposes. Whether it be 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.

Here you can find just a few examples of our foam cut to size templates. If you can’t find the shape you’re looking for, there are even more to choose from on our homepage. You can always choose our custom template option if you’re still struggling to find the right shape. If you need any assistance with your order, be sure to contact a member of our team.

Sofa Cushion Foam



Curved Sofa Cushion Foam



Bull Nosed Cushion Foam



Caravan Cushion Foam



Foam Wedges



Cutaway Corner Mattress



Custom Shape Foam

How We Cut Foam

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 can create products that 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 by the use of 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 in the most efficient way possible. You’ll likely have great difficulty finding an off-the-shelf foam case insert made to cater to your items’ specific shape. Instead, you’ll benefit much more from a bespoke foam insert made using CNC cutting technology.

Our CNC machines can accurately read CAD (computer-aided design) files. If we were to create a CAD file for your custom foam shape, it could then be converted to a CAM file which our CNC machines could replicate in foam. This process can then be repeated multiple times to create the desired number of custom foam products. Foam inserts, for example, could then go on to be used in retail products, on production lines, for promotional materials, or even within a toolbox to name just a few examples.

Manual Foam Cutting

We don’t just rely on computers to carry out our cutting 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 that upholsterers use to build and refurbish furniture. Meanwhile, the tilt knife allows us to precisely cut foam blocks at specific angles. This machine, for example, can be utilised in the production of certain foam cushions and mattresses.

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’s 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. Once the seal is broken, air is once again able to return to the foam and it will gradually begin to expand.

The method of mattress rolling makes it much easier for us and you 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 its original shape, but can take up to 24 hours. It’s also important to note that this method doesn’t damage the mattress. Foam is designed to be compressed and is a robust material; our mattresses are easily able to withstand this method of packaging.