How is it manufactured?

To manufacture foam, the chemical mix is poured continuously onto a moving paper or plastic film mould which is supported on a moving conveyor. As the expanding mixture moves down the conveyor, it is also changing from liquid to solid elastomer and is usually complete within the first 2 or 3 minutes (7 to 10 metres from the point of pouring). Sides on the conveyor allow the foam to rise into a “bun” or slab anywhere from 0.5 to 1.1 m high. The continuous slab is then cut, stored, and allowed to cure for up to 24 hours. The cured foam is subsequently fabricated into useful shapes.

Start of foam pouring process Formulation enters bottom of trough through feeder hoses.	Formulation flows out of trough onto conveyor.
The foam is conveyed through the foam machine tunnel, during which time it is formed into shape and length.