How is Foam Made? The Process of Foam Manufacturing

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

Have you ever wondered how foam is made? The manufacturing process for foam rubber is an elaborate one. A lot of work goes into making the foam products you likely use on a daily basis. From sourcing the raw materials to converting the foam into a finished product, let’s find out how it all works.

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. When ready, the chemicals are pumped into smaller heated holding tanks. The materials are kept separate from each other to prevent a chemical reaction.

Dispensing & Mixing Materials

Specific amounts of each chemical are fed from mixing tanks into a mixing head and then 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 that help to cause the foaming process.

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

Cutting and Curing Foam

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 many different types of products such as foam cushions, acoustic foam tiles, memory foam mattresses, custom packaging and much more.

We convert a variety of foam types to create a range of unique products. Our factory is equipped with many unique pieces of cutting machinery that enable us to do this. For example, our CNC router enables us to create and replicate more complex shapes with foam.

If you require foam cut to size, use our calculator for an instant quote. We can cut foam to practically any shape and size of your choosing. Our team of experts are also at hand to answer your questions and offer you advice. If you would like to speak to a member of our team, please feel free to contact us.

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 quickly as the next working day.