The Foam Factory

Cut Foam Easily with These DIY Open-Cell Foam Cutting Tips

Foam Factory — Fri, 17 May 2013 21:43:44 +0000

At Foam Factory, Inc., we offer a broad range of foam cutting services, from bulk runs in the tens of thousands, to incredibly precise, computer-controlled cuts made with a stream of water .005 inches in diameter. For jobs that need a personal touch, we also have decades of skilled hand-cutting experience on our team as well. If you need precision in your order, or thousands of identical pieces, Foam Factory’s custom-cutting services will exceed your expectations.

Serrated blades cut foam cleanly when you take your time

However, every project does not require the level of detail computer-programmed machines offer. Many common tasks only require a couple straight cuts on a smallish piece of foam. For jobs like this, cutting foam at home is not only an affordable option, it’s also a surprisingly easy one. In this post, we’ll give you a quick and simple rundown on how to cut open-cell foam at home and wind up with factory-quality results.

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Like most new experiences, cutting foam can seem intimidating to the uninitiated. The last thing anybody wants to do is accidentally ruin a brand-new foam insert or mattress topper. While understandable, this reluctance is actually unfounded, as the reality of the situation is that cutting foam is incredibly easy.

Sliced bread is a fitting analogy, as cutting bread is a great way to think about cutting foam. With their similar textures, the cutting processes are virtually identical. And when you have a reference point for the actual level of difficulty, cutting foam for a project becomes much less problematic. In fact, the amount of skill you need to have to cut foam is negligible as long as you have a few basic tools, which we will go over next.

The top priority when preparing to cut foam is a flat cutting surface that won’t be damaged. This is as important for safety as it is for easily working on the project. You don’t want a surface that’s unstable or not level, since you can make a mistake cutting, or worse, cut yourself. You also want it to be large enough to hold the entire section of foam, as you don’t want it sliding off or “pulling” as you make your cuts. Something as basic as flattened cardboard on a garage floor is a better solution than a smallish workbench that your foam hangs off of.

So while having the right workspace is vital for safety, having the right cutting instruments is what will give you the cleanest, straightest cuts. There are only two types of knives you should use to cut foam; both will need to be as sharp as possible, but neither should feature a flat, straight blade.

Option one is a serrated carving/bread knife. As mentioned earlier, cutting foam is essentially the same as cutting bread, so it only makes sense that you would use the same type of knife as well. When using a serrated blade, make smooth and gentle back-and-forth cutting motions through the foam. Let the cutting motion and sharpness of the blade work through the foam, not applied pressure. Starting at an edge of the foam and cutting slowly at a 45 degree angle with a serrated blade can give you a perfectly flush edge you probably didn’t think was possible at home.

Always use a straight-edge when marking off cutting lines

The other cutting style is a bit surprising to some people, but it works wonderfully. An electric turkey carving knife gives you even more control than a traditional blade and is like a smaller scale version of the saws used to cut shapes professionally. Just like when cutting with a standard knife, let the blade saw its way through the foam, rather than forcing it through with pressure. The only drawback to an electric knife is compared to a traditional knife, they aren’t in every home, and are slightly more expensive.

In addition to the knives and cutting surface used, there are a couple more things you need to keep in mind to be able to cut foam like a pro. The first thing to keep in mind is that you should never compress foam in an attempt to make a fast cut. Doing so results in uneven pressure that translates to a wavy, jagged edge when released. Cutting slowly with fully expanded foam only takes a couple minutes longer and is definitely worth the straight edges you’ll ultimately end up with.

The other item involves cutting when you are following traced lines. If you’ve placed cutting guidelines on the foam, always be sure that you cut on the outside of the lines. One, because a slight over-cut will compress into its case and look full, and two, an under-cut is a mistake you can’t undo. Over-cutting means you can always trim a little bit more off if needed. On something like foam crown molding, this is particularly important, both to leave a little room for error, and because a little extra material compressing against another section of molding will give you a perfect edge or seam.

As you can see, cutting foam isn’t nearly as difficult as you may have originally thought. If the project you’re considering doesn’t need the degree of precision that custom cutting services from Foam Factory offer, stick to these cutting suggestions and you’ll be have a great-looking project and a few extra dollars in your pocket.

Need Wholesale Upholstery Supplies? Try Foam Factory!

Foam Factory — Wed, 01 May 2013 21:55:15 +0000

These days, Foam Factory, Inc. is a renowned supplier of open-cell and closed-cell foam products and materials. But when they first opened more than 30 years ago, Foam Factory’s focus was on upholstery, from chairs and stools, to couches and cornice boards. Those roots are still part of Foam Factory’s business, and with the wholesale upholstery supplies they offer, they’ve made it the business of small companies and DIY aficionados as well.

Lux foam wapped in Dacron fiberfill

Featuring a product line that contains multiple cushion foam types, access to thousands of fabric patterns, and fiberfill cushion wrap (Dacron), Foam Factory is a great resource for small businesses in need of an affordable, wholesale source for materials, as well as individuals in search of quality upholstery products.

The most important characteristics of any piece of furniture are comfort and durability. Using poor-quality materials in an upholstery project can leave a seat looking great but feeling terrible, defeating the purpose of reupholstering. Selecting the proper upholstery foam for a project will give it looks, comfort, and longevity you will appreciate.

For many seat cushions, the HD36 and Lux family of foam is the right set of products for the job. Both are made in a regular formulation, as well as a high quality version that features additional density for increased longevity. HD36 is a medium-feel foam for individuals who enjoy a balance of comfort and support in their seating, and Lux offers extra firmness for individuals who appreciate more support in their cushions. While they offer different firmness levels, neither is too soft nor too firm, and their use will make an immediate and positive difference in any upholstery project. All four foam types – HD36 Regular, Lux Regular, HD36 High Quality, and Lux High Quality – are available in standard thicknesses up to 8”, so you’ll have no problem completing even the most demanding projects.

Foam Factory also stocks other foam types that are useful in upholstery besides the aforementioned Lux and HD36 varieties. For seatback and arm padding, Super Soft and Poly Foam are great materials to provide the correct balance of economy and function for parts that don’t have the same physical demands as a seating surface.

Open-cell poly padding foam

The seatback and armrest areas of chairs and couches mainly exist as comfort additions, since arm-less and back-less seating options are perfectly functional, proven by the wide-spread use of stools. This means they don’t have to bear the same amount of stress as a seating surface that holds a user’s entire weight. For these less-demanding upholstery areas, Super Soft and Poly Foam cushion and soften very well. True to its name, Super Soft foam is the most cushioning foam type Foam Factory offers, with a low ILD of 12, a measure of firmness. With lower density than Lux and HD36 foam varieties, these two types cost less as well.

To make upholstery projects even more comfortable, polyester fiberfill is yet another supply Foam Factory offers. Fiberfill is great for creating a fluffy, luxurious look under any upholstery project. Very compressible, poly fiberfill keeps seats looking full, but doesn’t take away from support. Instead, it offers yet another cushioning layer, great for plush couches and full-looking dining room chair pads. Foam Factory sells their fiberfill in 30”, 60”, and 88” sheet widths by the lineal foot or in 60’ and 120’ roll lengths. Spray adhesive is also available for more advanced upholstery projects.

All of the supplies mentioned in this post are available for purchase in small qualities or in bulk, no matter if you’re a residential customer with a one-time project, or a business after a dependable material supplier. On large-volume orders, Foam Factory offers price breaks as well, which also apply to both residential and commercial customers. If it’s fabric you need, stopping by Foam Factory’s brick-and-mortar Clinton Township, Michigan location gives you the chance to browse tens of thousands of options, such as suede, velvet, vinyl, and more.

If you’re trying to rebuild an old piece of furniture into something brand-new, Foam Factory should be your first and last stop for upholstery materials.

Foam in Place of Feet? Keep Your Boots and Shoes Looking Great With Foam Inserts!

Foam Factory — Mon, 22 Apr 2013 16:34:58 +0000

When spring peeks around the corner every year, people look forward to warmer weather more than anything. After what feels like ages of snow, ice, doom, and gloom, getting out the sandals, shorts, and t-shirts can make us feel like we’re spreading our wings for the first time.

But while cold weather is the last thing on our minds once the thermometer starts to rise, winter always returns, and when it does, we’ll need to layer-up again. For people who live in areas that experience all four seasons, it’s important to take care of winter-weather gear so it’s ready to go when the snow begins to fall.

Polyethylene cylinders showing the support they offer

For the heavy-duty boots and shoes we wear in the winter, the bottom of the closet often ends up being their summer vacation destination. But for taller footwear, particularly boots that rise above the ankle or up the calf, the “neck” of the shoe is not rigid and will flop over without the wearer’s leg holding its form. This can cause stress and stretch the leather, resulting in creases and wrinkles which prematurely age your shoes. To help prevent this, foam represents a surprisingly quick, affordable, and creative solution.

Polyethylene foam cylinders, commonly seen as as pool noodle toys or exercise rollers, are soft but rigid forms that, when inserted into a boot, help the shoe hold its form. Made in various lengths and diameters, finding a foam cylinder that fits your shoes is probably easier than finding shoes that fit your feet! A closed-cell foam, polyethylene is very easy to cut, so buying extra-long foam tubes multiple feet in length means you can support and protect multiple pairs of boots by trimming off sections from a single cylinder. Using a sharp, serrated knife, you can slice through polyethylene like you were cutting a loaf of bread. Trimmed to a length a little shorter than the height of the boot, you can slide the cylinders down to the heel and get a pair of shoes that stand straight up, without even seeing the foam support holding them upright.

In the before-and-after picture shown in in this post, you can see a pair of leather boots slouched over. With the foam cylinders inserted, they stand upright and hold their shape. For your uses, you’d want to trim off the foam sticking out of the boot, both for aesthetics and to use the material on another pair of boots, but we left them intact in the image to highlight the rigidity of the material and to show you don’t even need the largest possible diameter to get the job done.

In addition to function, foam shoe bolsters for shoes are just as useful for maintaining form, literally and figuratively! For people who have significant shoe collections, keeping them standing upright on display can tidy up a closet, make it easier to find the pair you’re looking for, or even help you pick the right shoes for an outfit. This support method is a great way to take care of rain boots, high-heeled boots, or even cowboy boots, year-round. Supporting boots with a foam cylinder can even make polishing and cleaning them easier. Halving cylinders length-wise also helps expensive dress shoes, flats, and low-ankle slide-ons keep their shape.

Foam Factory, Inc. sells many sizes of polyethylene foam cylinders, with seven diameters available, ranging from 1-1/2” to 6”, and three different lengths: 17”, 5”, and 70”. Custom-cutting services are available for sawing cylinders to exact sizes, as well as halving them length-wise for individuals who prefer not to make cuts at home.

If you’re looking for a way to keep your shoes and boots in good condition all year, or just need to organize your closet better, keep them in shape with polyethylene foam cylinders.

You can see Foam Factory’s polyethylene cylinder selection Here.

Build a DIY Beanbag with Foam Factory’s Custom Beanbag Chair Materials!

Foam Factory — Tue, 09 Apr 2013 18:53:34 +0000

At Foam Factory, Inc., we offer plenty of products that can help you over-achieve on a DIY project without going over budget. From couch cushions to crown molding, do-it-yourself foam products can make your life easier, more comfortable, and more enjoyable. Lately, Foam Factory has seen an increase in one particular project people are deciding to DIY, and felt it would be helpful to pass the idea to our customers.

Filling a beanbag liner with shredded foam

Homemade beanbag chairs and foam sacks have been growing in popularity recently, as people begin to tread farther off DIY ‘s beaten path. Whether they’re for a children’s bedroom, a school’s playroom, or a family’s theater or game room, beanbags built to suit your preferences and style can give you comfort and satisfaction in ways few other pieces of furniture are able to. And for people who want those benefits without the hassle and markups of big-box stores, DIY foam sacks offer a terrific solution.

The size of beanbags is what stifles many attempts to build or repair them, because sourcing materials in the quantities needed can quickly turn a simple project into a costly one. Just finding enough foam stuffing to fill a 6’, 5’, or even a 4’ diameter beanbag can be a headache, without even touching on how cost-ineffective purchasing small bundles of material becomes. The key is finding a retailer who offers affordable bulk orders while maintaining a retail side to their business, so individuals can place large, one-time orders. Fortunately, this is Foam Factory’s specialty.

With nearly 100,000 square feet of warehouse space and bulk orders leaving their doors daily, Foam Factory maintains a level of business that allows them to accommodate individual customers’ requests while keeping prices affordable. Foam Factory offers four different shredded foam types in bulk sizes that are perfect for a DIY beanbag, or re-filling or firming up existing beanbags.

Conventional shredded foam and charcoal foam are sold in 36” x 36” x 48” sacks, weighing approximately 30LB apiece, while 4LB density shredded memory foam is sold in 18” x 18” x 72” sacks which weigh about 15LB. The conventional shredded foam is also sold in the 18” x 18” x 72” size, weighing approximately 8LB. In addition to these plush open-cell foams, Foam Factory also offers shredded polystyrene foam, the filling classically associated with beanbags, in a 12” x 12” x 65” sack, weighing around 6LB. These foam types all offer their own set of benefits: the temperature-sensitive contouring of the memory foam, the plush cushioning of the conventional and charcoal foam, and the firm resilience of polystyrene. No matter your comfort preferences, one of these foam types will give you the perfect DIY foam sack chair.

For most people building their own beanbag chairs, acquiring the stuffing material is the hardest part of the equation. However, some individuals may not have the confidence in their sewing skills to create something durable enough to hold up long-term as a free-form seat. Others may have a perfectly comfy beanbag, but over time the cover has been stained, damaged, or torn. For those looking for the perfect cover to their DIY beanbag, Foam Factory offers completely customizable foam sack covers, with vibrant colors and terrific quality.

Foam Factory’s passion-suede cover options

Proudly hand-sewn in Foam Factory’s shop one at a time, each of their beanbag covers is made to last for years and look great doing it. Made of luxurious and soft passion suede, beanbag covers are available in 12 colors and 6 standard sizes: 3’ and 4’ round shapes and 5’, 6’, 7’, and 8’ rectangular shapes. Each cover features a heavy-duty zipper covered by protective flaps to keep the user comfy and the beanbag chair attractive.

In addition to their standard offerings, Foam Factory will custom-make covers in many non-standard shapes or sizes for a special order. And for people who aren’t crazy about passion suede as a fabric, Foam Factory also has 100 percent cotton twill fabric in eight rich colors that can also be made into a custom cover. For people who have the foam filling and the outside cover taken care, Foam Factory even offers a pre-made inner-liner of black twill in the six standard sizes. These allow you to remove your outer cover for periodic cleaning or laundering without having to deal with the hassle and mess of loose foam filling everywhere.

Ultimately, Foam Factory can accommodate your beanbag needs no matter where they fall. Whether you just need stuffing, you’re looking to build a completely customized beanbag chair, or you only require one component to repair a damaged beanbag chair or finish your own DIY foam sack, you don’t need to look farther than Foam Factory.

In addition to their beanbag chair components, Foam Factory also sells complete, ready-to-use foam sacks, ready to be shipped right to your door. You can see them Here.

Pick The Right Glue For The Job: How to Select Adhesives For Bonding Foam

Foam Factory — Fri, 22 Mar 2013 18:18:50 +0000

Whether you’re rebuilding the engine on a car or helping your child with his or her science project, things always go smoother when you use the right tools for the job. This is equally true in the world of foam, whether you’re a homeowner working on a DIY project or a business making custom seat cushions or foam mattresses.

Foam Factory, Inc. offers a broad selection of foam products, and along with them, spray adhesives formulated to work with every foam type they offer. This particular post will help you better understand why a process that seems so simple is actually surprisingly complex, and assist you in selecting the right adhesive for your project, with our detailed adhesive breakdown.

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First, a little background information on why gluing foam is so unique:

(L to R) 3M Super 77, Claire Mist, and Camie 373 Spray Adhesives

Different types of adhesive being required for foam is a result of the diversity present in foam materials. In terms of feel, looks, and performance, open-cell foam and closed-cell foam are obviously different products. However, those dissimilarities aren’t just surface-level differences, as the foam types are individually unique due to their chemical and molecular structures. So while open and closed-cell foams still belong to the same family, the compounds they are made of create a range of variables when it comes time to put the materials to use. In this instance, they affect how a particular foam reacts to adhesive. Depending on the foam type, some adhesives may not form a bond strong enough to last, while others can cause a reaction that physically damages or even destroys the foam.

Fortunately, this isn’t something that has just recently been discovered, and special adhesive formulations exist for properly bonding all different types of the material. Of course, multiple, similar options can always create confusion without knowing which works best for your application. To make things easier, we’ve created an itemized breakdown of our three spray adhesive varieties.

Under each type of adhesive we carry, we’ve listed and linked to the foam types it works best with, as well as what it should not be used with. Whether bonding two pieces of the same material, or gluing to most substrates, just find the foam you’ll be working with, and you’ll find the correct type of spray adhesive for your project!

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Spray Adhesive: Claire Mist
Do NOT Use With: Closed-Cell Foam
Use With: Open-Cell Foam
This includes all densities, colors, and firmness values of:

Poly Foam
Super Soft Foam
Dryfast Foam
Rebond Foam
Acoustic Foam
Speaker / Filter Foam
Polyurethane Anti-Static Foam
Talalay Latex Foam
HD36 Foam: Regular and High Quality
Lux Foam: Regular and High Quality
Charcoal Foam: Regular and Firm
Memory Foam

   -3LB ViscoSAVER
   -4LB ViscoPLUSH
   -5LB ViscoMAX

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Spray Adhesive: 3M Super 77
Do NOT Use With: Expanded Polystyrene Closed-Cell Foam (EPS)*
Use With: Most Closed-Cell Foams AND All Open-Cell Foams**
This includes all densities, colors, and firmness values of:

*3M Super 77’s formulation can physically melt EPS foam varieties, damaging and/or destroying the material.

**3M Super 77 bonds more strongly with open-cell foam than Claire Mist but is costlier. Claire Mist is the cost-effective choice for all but the most demanding open-cell foam projects.

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Spray Adhesive: Camie 373
Do NOT Use With: Open-Cell Foam OR Most Closed-Cell Foams***
Use With: Expanded Polystyrene Foam (EPS)

***Camie 373 is specially designed for use with Expanded Polystyrene Foam (EPS) to prevent damage that other adhesives may cause.

If you have more questions on how to bond foam once you’ve identified the right adhesive, see our PDF “How To Use Spray Adhesive With General Foam Products” or Contact Us for more information!

Complete Your Bedroom with Elegant Upholstered Headboards

Foam Factory — Mon, 04 Mar 2013 21:22:24 +0000

If your intentions are to turn your bedroom into a sleep sanctuary, you’ll have a hard time finding a better place to help you accomplish your goals than Foam Factory, Inc., with their line of latex, memory, and polyurethane foam mattresses, toppers, and pillows. In addition to your bed and the comfort products that go along with it, many people are surprised to learn Foam Factory also builds headboards, giving you the ability to tailor your bedroom furniture from head to footboard!

Soft foam bolsters are halved and used around headboards for banding

Headboards serve multiple purposes, from protecting the bedroom wall against dirt and wear, to offering something to lean against for reading or sitting up in bed. The one thing that remains constant in headboards, no matter how they are used, is that they instantly become the focus of your bedroom. Since the bed is traditionally the largest piece of furniture in a bedroom, the addition of a headboard simply ties the bed together with the rest of the room’s elements; much like a cherry on top of a sundae, or the crown on the king’s head.

For people looking to invest in an upholstered headboard, Foam Factory has been making soft, elegant headboards since they opened, with more than three decades of experience. Featuring a selection of in-house headboard ideas and designs, as well as thousands of covering fabric options, a headboard from Foam Factory can be customized to your exact specifications. Customers can even bring in their own designs and covering fabrics for custom fabric headboards.

Headboards are constructed on a ½ inch wood base with an additional ¾ inch frame built around it, giving them strength and stability. Atop that foundation, Foam Factory’s cushioning super soft foam is adhered and covered with polyester fiberfill batting, creating a full, fluffy look that’s soft to the touch. In addition to a plain, padded headboard, many other style variations are available. One of the most popular customizations for a headboard is banding, where a semi-circle of foam is added around the edge to create a border. On banded headboards, the fabric can be upholstered over the foam smoothly for a sleek, modern look, or in a gathered, ruffled fashion. Welting around headboards is also an option, which can add texture, style, and color accents. Tufting and buttoning is still another tailoring option for adding some style to your one-of-a-kind headboard.

If you’re furnishing a new bedroom or just looking for that last addition to tie it all together, a headboard may be exactly what you need, whether it’s for fashion, function, or to just protect your walls. Often, individuals who never really felt that they needed headboards for beds are often surprised at the difference they make in a room.

For more info on headboards from Foam Factory or to discuss custom design possibilities, give us a call or send us an e-mail through our Contact Us page. We’ll be glad to create a one-of-a-kind piece of furniture just for you!

Sitting Pretty: Outfit Specialty Seating Applications With Durable Rebond Foam

Foam Factory — Wed, 13 Feb 2013 18:40:17 +0000

When people are able to decide what kind of seat cushioning foam they put in their chairs or couches, they often say that they want the firmest, longest-lasting foam possible. Generally, this is said with traditional high-density foam for cushions in mind. However, many consumers aren’t aware that specialty open-cell foam types exist that can easily surpass standard cushioning foam in density, firmness, and durability. Open-cell rebond foam is one of these specialty materials.

Rebond Foam Sheets

Rather than a poured and expanded polyurethane product, rebond is created by bonding already-formed shredded foam under compression with adhesive. The bonding agents and compression combine to add strength and rigidity that allows the 1LB to 2LB density materials that typically make up rebond to be formed into a material with a 7LB-and-greater density. On the flip side, this is also why rebond material is generally too hard for comfortable use as residential chair padding and mattresses.

That isn’t to say rebond can’t fill a niche in the comfort industry, only that most applications don’t need the strength and firmness it provides. But for applications like industrial seating, as well as cushioning recreational vehicles, rebond provides durability with enough comfort to meet those uses’ demands.

Industrial, public, and commercial seating has a very different set of requirements than the seating in a living room set. Church pews or restaurant booths, for example, receive daily use and abuse that residential seating couldn’t and wouldn’t be expected to bear. Consider the pressure kneeling pew cushions receive, or the forces generated by people sliding on and off stools at bistros and pubs all day. This high-impact and omni-directional wear would turn lesser foam into dust, but when padded with rebond’s strength, these seats are able to handle the abuse while still being more comfortable than a wooden pew or bench. Downtime caused by reupholstering seats isn’t something most places can afford or want to subject their patrons to. Fortunately, rebond foam is able to provide the necessary long-term padding.

Another demanding application where rebond does what other materials can’t is in seating for recreational vehicles. ATV seats, motorcycle seats, and even a snowmobile seat not only have to endure punishment from the rider’s movements, but also the constant vibrations created by the engine. These motor vibrations can accelerate the breakdown of a material not intended for such use, but again, rebond is able to last where other materials cannot. Rebond is firm enough to give riders the support needed to stay confidently in control of their vehicles, while also being able to be customized to the rider’s comfort preferences. Custom motorcycle seats are particularly popular, as they are able to be cut from larger blocks or glued together from sheets. Whether seats are worn out after years of use or don’t offer the right fit, a DIY motorcycle seat made of rebond foam can improve the open-road experience.

The versatility of foam materials is hard to match when you consider how many varieties of foam there are, and all the places you can find them in use. Even for specialized applications, there’s often a unique foam that’s perfect for the job. Rebond’s ability to perform in applications that require durable seating is a perfect example of this.

Foam Factory, Inc. stocks 7LB, 70ILD rebond foam in 1 and 2 inch thickness and sheets in two different sizes. For more information, visit its product page on TheFoamFactory.com.

Taking a Closer Look at Foam: Part 2 – Closed-Cell Foam

Foam Factory — Thu, 31 Jan 2013 18:29:18 +0000

For the second part in our review of the cellular structure of our foam products, we take a look at the more rugged and durable closed-cell foams!

For the previous post in our two-part series, click here: Taking a Closer Look at Foam: Part 1 – Open-Cell Foam

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Closed-Cell

Top to Bottom: Polystyrene (EPS), Polyethylene, Polyethylene Roll, Gym Rubber, Cross-Linked Polyethylene (XLPE), Neoprene Click to Enlarge

While there is relatively little cellular variation among open-cell foams, closed-cell foam offers a range of cellular characteristics that can easily differentiate themselves from one another and are able to be seen with the naked eye.

Expanded Polystyrene (EPS) has the most unique foam cell structure among closed-cell foam, and as a result, is the most recognized. The ubiquitous white foam, typically seen as coffee cups and packaging materials, is also known as bead board because of its cellular structure. During the material’s formation, tiny beads of styrene expand to more than 40 times their original size and are compressed together into blocks, sheets, and molded shapes. These beads are easily seen in the structure of the material, and being about the size of a BB, can be picked out and held in your hand. Because of the size of these beads, EPS requires hotwire cutting for smooth edges, otherwise it tears and flakes.

Polyethylene is closed-cell foam that appears more plastic-like in appearance than its counterparts. Made in various colors, the material has a sheen, as opposed to the matte finish of some closed-cell foams that appear more rubbery. The cells of polyethylene are rather large, similar in size to Dryfast, but are completely sealed off to one another as enclosed cells. The size of the cells in polyethylene are impacted by the density of the material as well. Lower density polyethylene has larger cells and high density has smaller cells.

Very close structurally to standard polyethylene is polyethylene roll. Quite similar cellularly to standard polyethylene, the roll contains a much finer and consistent cellular structure but has some added sponge-like characteristics as well. Also unique is the skin on the top and bottom of sheets of polyethylene roll; not perfectly smooth as cells are still visible, but firmer than the foam’s interior.

Also similar to polyethylene is gym rubber, though its appearance can vary much more than the consistent polyethylene. As the name implies, gym rubber is more rubbery and less plastic-like than polyethylene, giving it a flatter-looking aesthetic. The cells in a gym rubber sheet are obscured by the smooth skin of the material, but a cross-section of the material shows a bubbly cellular setup. More than any other material Foam Factory stocks, gym rubber can have the largest variation in cellular structure, ranging from minuscule to large cells.

The two foams with the finest cellular structures are the neoprene and cross-linked polyethylene (XLPE) varieties. The look and feel of these materials may make you think otherwise, but they are also constructed of cells, albeit incredible small ones. That cell size produces a material that looks more like a solid piece of flexible plastic or rubber than something built like the open-cell materials.

Both neoprene sheets and XLPE are consistent all the way through their forms, without getting denser near the outer edges of the sheet. Despite the visual similarities though, the compounds used to make these two materials produce different physical characteristics. The neoprene is the more rubbery material, softer in most formulations than XLPE, with more flexibility in most cases as well. Cross-linked polyethylene meanwhile, has more rigidity while usually being lighter. In thinner sheets, these two foam materials can be easily cut by hand with a sharp, non-serrated blade.

While there are many factors that affect a foam’s performance, having a little insight about a material’s structural makeup can give you a good starting point for deciding what might work well for you.

Taking a Closer Look at Foam: Part 1 – Open-Cell Foam

Foam Factory — Thu, 24 Jan 2013 17:01:40 +0000

If you were to survey a handful of people on the street, you would be hard-pressed to find a person who doesn’t know what you’re talking about when you say the word “foam.” However, part of what makes this material so interesting is that while everybody knows what foam is, the type of foam people first think of can generate all kinds of different answers. One person could envision memory foam or polystyrene just as easily as another could think of neoprene or gym rubber.

Of course, one type isn’t more correct than another, but with this amount of diversity, there is a bit of ambiguity that can accompany the term. Here at Foam Factory, Inc., we wanted to offer a more detailed glimpse into the structure of our materials, so you can see some of the characteristics that help define the foam you’re familiar with.

Open-Cell Foam

Traditional polyurethane foams are very similar structurally, providing a recognizably soft and squishy feel. Colors aside, Foam Factory’s memory foam, Lux foam, HD36 foam, charcoal foam, and poly foam varieties are all similar on a cellular level, though the compounds used to make the materials may differ.

Top: Standard Polyurethane Foam, Middle: Latex Foam, Bottom: Dryfast Foam (Click to Enlarge)

Foam cells, both open and closed, are bubbles that have expanded from the liquid mixture of the foam during its formation. In open-cell foam, these bubbles expand until they burst, leaving behind an interconnected structure of foam called struts. In closed-cell foam sheets, cells do not rupture, and the thin surfaces between the struts are called windows.

Without holding a polyurethane open-cell foam sheet inches from your eyes, you likely won’t notice the material’s structure unless you’re specifically looking for it, save for a few of the larger ruptured cells. These foam cells are smaller than a millimeter in length and create a structure that’s very consistent as a whole. If you inspected a cross-section of open-cell polyurethane foam with a magnifying glass, you would see a structure like in the picture that looks like millions of popped bubbles stuck together.

Depending on the cutting process of a material, some polyurethane open-cell foams look like they sparkle. This occurs when the foam surface contains the aforementioned windows that didn’t rupture in the foam’s formation. These reflect light, making them noticeable when looking across the form, but are minimal compared to the actual number of cells in an open-cell material. Over time, these remaining cell walls break down with use, giving the foam a flatter, more matte-like appearance.

Latex foam is another variety of open-cell foam, and is very similar to polyurethane foam with a few minor differences. Depending on the type of latex, some of the cells may be slightly larger than those in polyurethane foams. This varying cell size, combined with its cream color, gives the material a fluffy appearance, a lot like Angel Food cake. One distinct quality about latex that sets it apart from other open-cell foams however, is the way it’s made. Poured into a pincore mold, spots evenly dot the surface like ventilation openings. The metal pins that make these holes are slightly smaller in diameter than a pencil, and depending on where a cut is made in the foam, the canals left in the material for ventilation may be obvious because of the depths to which they extend. They are an important part of the material’s formation however, and should not in any way be considered a defect.

Dryfast foam is easily the most unique material among Foam Factory’s open-cell foam types. Designed to permit the passage of both water and air, the cells of Dryfast are easily seen with the naked eye. Juxtaposed against traditional polyurethane foam materials, these cells are massive, with some being 3, 4, or 5 millimeters in diameter. The thin cell struts, compared against the comparatively large pores, almost make Dryfast appear wiry. Despite that, Dryfast is strong enough for use in outdoor seating cushions and marine foam pads, attesting to the resilience of the material.

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For the next post in our two-part series, click here: Taking a Closer Look at Foam: Part 2 – Closed-Cell Foam

Enhance or Unwind From Workouts With Foam Rollers

Foam Factory — Tue, 08 Jan 2013 15:04:08 +0000

If you come home from a long day at work with a sore back, find yourself stiff in the morning, or are looking to optimize your workouts, foam rollers are a product not to be overlooked.

White and charcoal polyethylene rollers

Versatile and resilient, closed-cell foam rollers can provide comfort and strength that people may not realize until after experiencing it firsthand. Great for augmenting self-massage, stretching, or exercising, polyethylene foam cylinders can make a big difference in your life.

Available in a substantial size range, foam bolsters and rolls are made to fit virtually any purpose. The greatest benefit of polyethylene foam being used for a roller is the resilience of the material. In 2LB densities and greater, appropriately sized polyethylene rollers are able to support the body weight of most people when used as an exercise bolster.

The simplest way to use a foam exercise roll is as an aid for stretching. Strong enough to support the weight of a body, polyethylene rollers are firm without being uncomfortably hard. Augmenting an after-work or post-workout stretch with rollers can give you an increased range of motion that helps better relieve stress and muscle tension. Many people who work in an office setting spend their days at chairs or desks that make them hunch over in a tight space that’s not conducive to proper body alignment. Using a foam roller vertically along the spine, horizontally under the small of the back, or either way along the shoulders can help you unwind with a relaxing stretch in a way that a padded floor mat can’t provide.

In addition to stretching, many people use foam rollers in a similar way for self-massage. The supportive firmness of polyethylene rollers allows you to use your own body weight to deeply massage muscles and work out knots. Resting against the roller with your body weight and slowly rocking yourself across the foam and cylinder can target sore muscles or help unwind after a strenuous workout. Some areas are difficult to directly address by hand if you’re feeling discomfort, but foam rollers allow you to target virtually any area of the body. Even if only used for treating occasional aches and pains rather than as a daily regimen, self-massage can help work out the kinks and knots that pop up every once in a while. Routinely exercising with foam rollers can also help with flexibility, which helps reduce injuries during exercise. They also help increase blood flow and are a great way to warm up before activities or cool down after.

Polyethylene cylinder size comparison

In smaller sizes, foam bolsters can be a supportive boost behind the knees, under the back, or beneath the ankles when you’re relaxing. Being round, a foam back support bolster is also useful with balance exercises, as muscles flex and contract as you work to maintain your position atop the roller.

Foam Factory, Inc. offers a selection of polyethylene foam rollers in a 2.2LB density that is firm and supportive, but still cushioning enough to use comfortably. The best sizes for exercise and stretching are the 3, 4, 5, and 6 inch diameter rollers, though 1, 2, and 2 ½ inch diameter rollers are also available should you have a special purpose for a smaller size. Standard lengths include 17, 35, and 70 inches long, though Foam Factory can easily cut any of their rollers to a custom size, down to a single inch. Additionally, Foam Factory can halve rollers horizontally to create two hemispherical bolsters with a flat side. Cutting a roller in this fashion is beneficial for people who want some of the resistance and support a roller provides, but not in the heights the full-sizes offer. They also create a surface for balancing exercises with a little more stability than the full cylinders offer.

If you’re searching for a simple and affordable way to improve your comfort, whether you’re lounging at home, relaxing after work, or recovering from a strenuous workout, polyethylene foam rollers are a practical and easy way to unwind and feel good.

NOTE: Before starting or altering a health or exercise regimen, please consult your physician.