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Memory Foam

We stock a wide variety of foam grades and types including memory foam. GB Foam has been in business for more than 45 years and utilises some of the most advanced cutting machinery to bring you foam in all manner of shapes and sizes. Memory foam is one of the most popular foam types we work with. It was originally developed by NASA’s Ames Research Center. Nowadays, many of us choose to sleep on top of it for maximum comfort.

Below you’ll find just a few of the finished products GB Foam Direct offers. This includes pillows, wheelchair cushions, foam crumb and upholstery sheets. We also have a range of different mattresses for you to choose from.

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.

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.

40 Years In BUsiness

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

Hand Made In The UK

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

ISO 9001 Quality

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

Super Fast Delivery

All orders placed before 11:00am will be despatched for next working day delivery

5 Year Guarantee

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

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 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.

Memory Foam Specifications

GB 55M – Memory Foam
AVERAGE NET PIECE DENSITY 47.5-52.5 Kgm3 BS EN ISO 845 : 2009 (ISO 845: 2006)
TENSILE STRENGTH 50Kpa min BS EN ISO 1798: 2008
ELONGATION @ BREAK 100% min BS EN ISO 1798: 2008

Questions & Answers

If you have questions about this foam, you may find the answers you’re looking for below. Remember, you can always contact our team for assistance if you need any further help.

Is Memory Foam Good To Sleep On?

Yes, memory foam is good for sleeping on, however, most people will find that alone, it doesn’t offer enough support. This type of foam is best used as a topper to enhance comfort. It is best used in combination with a firmer support layer of foam.

Is Memory Foam Expensive?

Compared to some other grades of polyurethane foam, memory foam does tend to cost a bit more. However, it’s often used more sparingly than other types of foam. For example, in our classic mattresses, we layer 5cm of viscoelastic foam on top of a 16cm support layer of foam to achieve an ideal level of support and comfort.

How Can I Tell When My Foam is Worn Out?

This is a thermo-reactive type of foam that responds to sources of heat, conforming to areas where pressure is applied. Once pressure is removed, the foam should gradually return to its original form. Worn-out memory foam may take much longer to do so or never fully return to the original form.

Does The Foam Smell?

On a rare occasion, you may find that your memory foam has a distinct odour. This smell is caused by off-gassing and is found to occur with many household items; it is normal and not harmful. The smell should subside in a number of days. Allowing your foam to “air out” in a well-ventilated area may help accelerate the process.

Can Dust Mites Live in Memory Foam?

This type of foam is naturally hypoallergenic and antibacterial. Having these handy qualities means that dust mites and other microbes will not live on it. It’s particularly beneficial for those with various allergies and asthma. It’s what makes this type of foam especially beneficial for sleeping on as allergy and asthma sufferers will be not be affected in the way they could be with certain other materials.

Where Can I Buy Memory Foam?

At GB Foam Direct, we sell memory foam in sheets, as finished products (such as mattresses) and in cut to size parts. To buy custom cut parts, you can follow the steps on our homepage. All you need to do is select an appropriate shape, input your measurements, choose the right foam, select any addons and place your order. If you can find the shape you need, choose the custom option and you’ll be able to upload your own template for our team to work from. You’ll find everything else here on our dedicated page. Remember to contact our team directly if you can’t find what you’re looking for or have any other questions you’d like us to answer.

Is Memory Foam Good For Side Sleepers?

Memory foam is popular with side sleepers due to the way in which it easily moulds around the shoulder and hips. By doing so, it can help to relieve pressure on prominent areas of the body and can help to improve alignment. If you’re looking for a way to improve the quality of your sleep, this foam could be what you’re looking for. Be sure to check out our mattresses and pillows above.

Can I Order Layered Foam From You?

It’s no problem if you’d like us to layer your foam up. If you’re ordering two different types of foam our team can laminate them together for you. Just place an order for a base layer and a top layer and ask for the two pieces to be laminated when promoted to leave notes for our team at the checkout.

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