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Understanding Foam Converters in Custom Foam Solutions

The process of foam conversion is what enables custom foam solutions to be designed for just about every need. Foam converters play a key role in ensuring that foam is ultra versatile – and that it can be used for anything, from packaging to cars, PPE and bedding. When it comes to creating foam solutions, foam converters have a key role to play.

How does foam conversion work?

It is essentially any process that can be used on foam blocks to create pieces of particular sizes, dimensions and features. This could be something as simple as splitting, for example, which is where large foam blocks are split down into sheets of foam. Where a sharp blade is used to cut foam down to size this is called band-knifing and is also part of the foam conversion process. Other cutting processes that are involved in foam conversion include die cutting, log cutting, routing and contour cutting. Other phases of foam conversion can include:

  • Lamination, where foils, self-adhesive backing or other substrates are being attached to the foam.
  • Spray coating with a fine PVC mist to create a barrier and seal holes.
  • Kiss cutting, which creates 2D shapes with a self-adhesive backing.

Which foams can foam conversion be applied to?

Foam converters are vital for making any foam fit for purpose and that includes some of the most commonly used foams, whether that is neoprene (formulated for its resistance to oils and chemicals), PVC foam – which is incredibly widely used because of its softness and flexibility – as well as silicone, which is a closed cell foam with especially stable and non-reactive properties. Other types of foam that frequently go through the foam conversion process include ethylene propylene diene monomer (EPDM), vinyl and polyurethane foam. The foam conversion process may involve using more than one type of foam at a time in order to create custom solutions.

Where do we see custom foam solutions used?

Foam converters make it possible for custom foam solutions that appear across many industries and sectors. These include:

  • Automotive – You’ll find foam conversion used to create everything, from tubing to steering sections.
  • Construction – Foam can be converted into insulation and roof membranes and is also vital when it comes to sealing in doors and windows.
  • Electrical and heating – In this context, foam converters create components for products that require cold storage or thermal applications, as well as electrical casing.
  • Leisure – Here, foam conversion is used to create custom foam solutions for a wide range of products, including seating and cushions, cookware, mattresses and marine floats and fenders.
  • Medical – From cosmetic implants to bandages and dressing, custom foam solutions created by foam converters are used everywhere.
  • Other – From PPE for the armed forces to packaging, custom foam solutions are an essential part of many areas of life.

Foam converters make custom foam solutions possible, transforming blocks of many different types of foam into products and components that are used across many different sectors.

Find out more about how Kewell Converters can help you with your specialist foam conversion need Contact us today.