How Foam Sheets Are Made: A Look Into The Process

Foam sheeting has become a popular material for numerous industries because it has many different applications. These lightweight sheets with flexible design are used for everything from packaging to crafts. It is a popular material for its insulating properties; it’s great for cushioning, and some types of foam sheets are excellent as a sealant. Even though foam sheeting is very popular, very few people know how this material is made. 

In this article, we will take a brief look at the manufacturing process of foam sheeting.

01. Raw Materials Are Selected

The foam sheet manufacturing process starts with materials in their raw form. Foam sheets are mostly made from three materials; 

• Polyethylene (PE)
• EVA (Ethylene Vinyl Acetate)

Each of these materials will help develop foam materials with a suitable density, softness, or durability. 

02. Mixing and Blending

The base materials are combined with a specific resin, colourant or dye, and additives. Blowing agents - chemicals that release gas when heated - are also introduced to create tiny air cells within the foam.

The batch is then mixed to form it into a uniform colour and consistency. 

03. Moulding

Different extrusion and moulding methods can be used for creating different types of foam sheeting. These can include methods like the following:

04. Foaming and Expansion

During moulding, the blowing agents are activated by heat, causing the material to expand and form millions of tiny aircells. This results in the lightweight, flexible nature of foam sheets.

05. Cooling and Curing

After the blowing agent activates, the foam materials are kept in their mould shape so they can cure and set. Once cured and cooled, the foam materials will hold their shape without shrinking or warping. 

06. Cutting and Finishing

Foam can be sliced into sheets of any thickness. They can also be rolled, laminated, embossed, or die-cut to create different finish effects or textures. Some foam sheets also get adhesive backings so they can easily be installed.

07. Quality Control

All foam sheets are quality tested before they aresold. The foam sheets are tested for their density, thickness, compression, and recovery rate, and the consistency of the foam and bubbles throughout the sheets.

08. Distribution

After ensuring the quality of the sheets, they are distributed to all sorts of industries. The sheets can be used by manufacturing industries to create a wide range of materials like cosplay, yoga mats, cushions, and crafts. Building and construction industries also buy these sheets to use them in soundproofing, insulation, eaves filler or for other construction purposes.

Buy Quality Foam Sheets 

It is very interesting to see how these sheets are made. The production methods also give us a little bit more insight into how these sheets are moulded so they can have the desired qualities. At Gardiner Australia, we specialise in foam sheet manufacturing. Our company offers a wide range of foam sheet types to choose from, and we can supply you with all the foam sheeting you could possibly need.

Contact Gardiner Australia today to discuss your needs or place an order for premium foam sheeting.