Christian Cavallo. Foam is a ubiquitous material in modern life, being used in cars, furniture, insulation, toys, equipment, fasteners, and many more products; but what is foam? Its technical definition is a mass of small bubbles trapped in either a liquid or solid, creating a sponge-like air-filled matrix. This definition still leaves much to the imagination, and so it is no surprise that there are many kinds of foam.
Some examples of foam types used in industry include:. The type of foam used in an application depends on its desired mechanical properties and specifications. The two most common foams used in industry are polyurethane and polyethylene foam and these can be found in mattresses, foam board, furniture, packaging, electronics, insulation, and much more. There is a good chance that a person has some version of these two foams, along with other types in their house at any given time, as they are vital components used in many industries.
To learn more about these materials, read our articles on the types of foam used in industry and all about closed-cell spray foam. The raw materials used will make each foam differ slightly based on density, thermal properties, and stiffness, and are designed with specific intentions in mind.
Raw materials such as polyol, polyisocyanates, water, additives, surfactants, and more are used to achieve a wide range of foam types. Foam is manufactured by dispensing these materials into mixing tanks and allowing them to chemically react, where they are then dispensed onto a moving surface or conveyor, forming the raw stock.
There are specific procedures used for each type of foam, but all are generally straightforward and driven by the desired material specifications. Foam suppliers can either supply foam produced by their company or can simply distribute various foam types from other manufacturers. In either case, foam manufacturers and suppliers will provide material specifications such as density, working temperatures, stiffness, etc.
Table 1 below contains relevant information on the top foam manufacturers in the USA listed by annual sales, as determined by Foamfabricating. Dashes indicate where information was unavailable on the Thomas Platform. Additional details about each company are included below such as headquarters location, the number of employees, year founded, and brief company summaries.
American Excelsior Company. American Foam Products. Heubach Corporation. Wisconsin Foam Products. Design Converting, Inc. Luxaire Cushion Company. Thrust Industries. American Excelsior Company is a manufacturer of packaging, cushioning, engineered foam, erosion control solutions, engineered wood fibers, and foam specialty products.
Flextech is a foam fabricator and engineered foam solutions provider based out of Saint Louis Park, MN. They specialize in custom packaging solutions as well as rapid prototyping, foam cutting, and foam bonding capabilities, and will call, design, develop, draft, and deliver custom foam products using their experienced team of engineers.
Heubach Corporation is a leader in flexible material manufacturing, having over 25 years of experience fabricating foam, CNC cutting, water jet cutting, laminating, die-cutting, rotary cutting, material skiving, heat thermoforming, slitting materials, heat bonding, and assembly. Home About us Our expertise Technology Bonded foam. How is PU foam made?
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Various thicknesses of polyester fibre can be cut and wrapped around foam cushions to give them a crowned or rounded look once they are stuffed into the fabric casing. Pieces of foam or layers of different firmnesses can be joined together using a clean and safe water based foam adhesive. Quilting of Covers. Foam and fibre are quilted into mattress fabrics to give a mattress a more comfortable look and feel. The mattress industry as a whole uses lighter weight grades for quilting foam.
Therefore, it is always better to keep the quilting in your cover to a minimum and go with a thinner mattress that is made with a heavier density of foam. Cover Sewing. Once the quilted fabric is cut to the required size the edges are surged together to keep the fabric from fraying. The sewn pieces are then passed on to the mattress closer. Mattress Closing. Material is sewn around the mattress with a moving sewing machine known as a mattress closer. Mattress closing is used for the mass production of mattresses of the same size and grade for commercial applications.
Better custom mattress manufacturers, with nothing to hide, make removable zippered covers allowing you to inspect the inside of the mattress and give you the option of making changes to your mattress should the need arise. Main Menu. Our Community Mattresses How to buy the best custom mattress at a great factory direct price. Foam Koosh is the best natural High Resiliency foam for sitting or sleeping. Log In. Email Address. Log in. Forgot password? Create your account.
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