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How is Foam Made? Foam Rubber Manufacturing

How is foam made?

Here at GB Foam Direct, we specialise in converting foam rubber into a variety of bespoke products. From acoustic foam products to mattresses and replacement sofa cushions, we’ve created a lot of different things throughout our 40+ years of service.

We stock a wide range of unique foam grades such as memory foam, reticulated foam, soundproof foam and much more. The foam rubber we convert is sourced from some of the world’s most established and trusted manufacturers. After all, product quality is our priority.

Manufacturing Foam Rubber

Have you ever wondered – How is Foam Made? The manufacturing process for foam rubber is an interesting one. So, let’s find out how foam is made and how it becomes a wide range of unique products.

How is Foam Made – Preparing the Materials

Liquid chemicals are first delivered to foam rubber manufacturing plants. These generally arrive by railroad or tank trucks. The materials are then stored inside large holding tanks until they are ready to receive further attention.

From there, the chemicals are pumped into smaller heated holding tanks. Materials must be kept separate from each other if they are at risk of chemically reacting.

Dispensing & Mixing Materials

Specific amounts of each chemical are fed from mixing tanks into a mixing head. Here they are blended together. The majority of foam rubber consists of the following raw materials – 50% polyol, 40% polyisocyanates and 10% water/other chemicals. These are reactive materials which help to cause the foaming process.

Once properly blended together, the mix is poured onto a conveyer belt, where it travels through a foaming head. After this, the mix begins to rise, cure and form what is known as slabstock.

Cutting and Curing the Foam Rubber

As the slabstock moves along the conveyer belt, it travels through a large horizontal bandsaw. This cuts the slabstock into smaller more manageable blocks (approximately 12ft long). Once the slabstock has been cut, the blocks are left to cure at room temperature for around 12 hours.

The final product is monitored and tested to look for various properties. An ILD (Indentation Load Deflection) test, for example, is performed to measure the load bearing capacity and spring tension of the foam.

Converting Foam Rubber

Various types of foam rubber blocks are purchased by and delivered to professional foam converters such as us. Here, we can convert it into various products for everyday use.

We convert a variety of foam types to create a range of unique products. Our factory is equipped with many pieces of cutting machinery which enable us to do this.

If you require foam cut to size, why not use our calculator for an instant quote? We can cut foam to practically any shape and size of your choosing.

GB Foam Direct is considered the fastest supplier of foam cut to size online in the UK. In many cases, we can have your order delivered to you as quick as the next working day.

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