Foam materials play a crucial role in a wide range of industries and applications, from bedding and furniture to packaging and insulation. This guide is designed to help you navigate the different types of foam used for sofa cushions, outdoor furniture, and large-scale industrial purposes.
Drawing from our extensive experience in the foam cutting and burning tool industry, our team has curated this comprehensive guide to popular foam types. Here, you'll discover a variety of foams available in different sizes and densities to suit your specific needs. We're excited to share our expertise and insights with you.
Polyurethane Foam
One popular and adaptable kind of foam is polyurethane. It comes in various kinds of densities and firmness, making it appropriate for a wide range of uses. It is utilized in the great majority of interior furniture, both domestically and worldwide. Because of its superior comfort and insulation qualities, this kind of foam is frequently used in carpeting, mattresses, cushions, and insulation. However, there is also PU foam or flexible polyurethane foam.
Due to its open-cell structure and low weight, flexible polyurethane foam, or PU foam, is perfect for usage in a wide range of items, such as mattresses, furniture cushions, car seats, and medical applications, just like casual polyurethane foam. You most likely come into contact with PU foam goods on multiple occasions a day without even recognizing it. PU foam is a soft, low-density foam because of its open-cell structure and lightweight nature. We suggest starting with a Knife edge, Scallop, or V-Tooth band knife blade if you don't have much expertise in cutting low-density foam.
Memory Foam
Memory foam, a kind of polyurethane foam also commonly referred to as viscoelastic foam, is widely recognized for its ability to be an incredibly soft, temperature-sensitive foam that molds to the shape of the body and offers superior pressure relief. Since memory foam was created by NASA researchers who were entrusted with creating a more comfortable foam for test pilots and spacemen, you can appropriately refer to this foam as space-age foam.
This foam material adapts to the shape of the sleeper by reacting to the body's heat. Memory foam is frequently utilized in medical applications, cushions, and beds. As opposed to ordinary flexible PU foam, which feels more bouncy, memory foam includes extra chemicals in it that make it more viscous and dense. The density of memory foam actually varies between two and eight pounds per cubic foot. Therefore, if the memory foam is thicker, you may need to upgrade to a sharper blade, such as a scallop or V-Tooth band knife blade, in order to cut through it. A knife edge blade may cut through less dense memory foam with ease.
Polyethylene Foam
Polyethylene foam is a closed-cell foam with exceptional shock absorption and cushioning properties. This foam material is commonly used in packaging, sports equipment, flotation devices, and automotive applications. Water rolls off closed-cell foam, which makes it a resilient choice in demanding environments. Because of its high density and firm structure, polyethylene foam has dozens of possible industrial applications.
Similar to polyurethane foam, polyethylene foam (PE foam) is also lightweight, but its closed-cell structure makes it more durable and rigid than other low to medium-density foams. PE foam is highly resistant to chemicals and moisture, and it has superior vibration-dampening and insulation properties. These combined qualities led to frequent PE foam use in packaging products (fragile or otherwise). Since PE foam has a closed-cell structure, you’ll need a slightly more aggressive blade to cut through it. We would typically recommend starting with a V-Tooth or C-Tooth band knife blade, but if you’re looking for a cleaner finish on the cut, then a Scallop blade would likely be the way to go.
Neoprene Foam
Neoprene foam is a flexible and durable foam that exhibits resistance to water, oils, and chemicals. It is often used in wetsuits, sports equipment, gaskets, and sealing applications. Neoprene foam provides excellent insulation and cushioning properties. Neoprene is most commonly known for its use in wetsuits. It comes in a layer of rubber, usually coated on one or both sides, with a thin layer of nylon material.
Neoprene foam is a material that is similar to rubber in that it is considered to be an elastomer (a natural or synthetic polymer that has elastic properties). It is a flexible, durable, and soft sponge rubber that is commonly used in many products across the medical, aerospace, and industrial industries. The material is available in both closed-cell and open-cell variants with each having its strengths. Closed-cell neoprene foam is waterproof, which makes it ideal for gaskets, while open-cell neoprene foam allows some air and liquids to pass when it is not fully compressed. This can make the material ideal for industrial filtration foam.
Neoprene foam is an ideal choice for industrial wetsuits, sports equipment, and gaskets, as already mentioned. Its properties include lightweight, vibration-dampening capabilities, and high chemical resistance. It is also a good insulator and is physically tough, durable, tear-resistant, and resistant to heat and flames. Moreover, neoprene foam can be used with a variety of adhesives and meets many industrial quality and safety standards, just like PU(polyurethane foam) and PE(polyethylene foam). Additionally, it has qualities like naturally form-fitting, increasing its ability to properly form an airtight seal; it has a good compression set resistance, stress relaxation, and compression recovery. It will not break down when it comes in contact with water or oils and won’t degrade due to exposure to sunlight, ozone, and other weather conditions.
Polypropylene Foam
Expanded Polypropylene (EPP) is a foam that provides excellent energy absorption and is, therefore, an outstanding foam for impact protection. EPP is popular for its high-quality thermal insulation, buoyancy, water and chemical resistance, and exceptionally high strength-to-weight ratio. It is also 100% recyclable. This material is used in applications such as HVAC enclosures, impact protection, and storage protection.
Expanded Polyethylene (EPE) is a soft, lightweight, flexible, and non-abrasive foam that is highly resistant to water, oils, and chemicals. EPE has a high weight-to-strength ratio and high thermal resistance, which allows it to be heated, reused, and recycled many times. It has excellent resistance to shearing from concentrated stress points.
Understanding the different types of foam and their specific applications is essential for making informed decisions in various industries, from furniture and bedding to packaging and insulation. This guide has provided an overview of popular foam materials, their properties, and ideal uses, helping you navigate the diverse world of foam products.
We hope this guide has offered valuable insights into the versatile and indispensable nature of foam. Whether you're crafting custom cushions, designing outdoor furniture, or working on large-scale industrial projects, the right foam can make all the difference.
Happy crafting and creating with foam!