foam rubber
foam rubber

Fabricating Process 




Blocking Saw


The blocking saw is the first and most important step of the PU cutting process.

PU is supplied in very large buns. Many times a full bun is more material than a customer needs.The blocking saw allows us to cut smaller blocks that will give you a lower minimum quantity.

Sometimes PU is needed in a hard to yield size. By blocking the material into smaller sizes and then cutting the blocks in different directions will often allow us to utilize the material much more effeicently.


Remember! Better yield, better deal!







A slitter cuts PU blocks into sheets. PU buns do not always run the same height and sometimes we can get more or less sheets out of blocks due to this irregularity. The quantity of your order may have to change to compensate for this variance. Our slitter can also cut a block into multiple thicknesses and quantities. This helps us utilize the full height of the block. It also allows you to mix your thicknesses to

match the blocks height. 







The convoluter cuts PU sheets down the middle creating two wavy sheets that have peaks and valleys that nest together. This saw is truly amazing. These squared fingered pins, rotate pulling and tugging on the material to destort and stretch the foam prior to it being cut. When the blade passes through the distorted material it cuts a straight path. It is not untill the foam rebounds back to its original sheet size do you see the convoluted cut.


Like all foam material we need to know the thickness, the width, and the length in order to generate a quote. Convoluted requires two more pieces of information. The first thing we need to know is the BASE THICKNESS of the convoluted. The base is the distance from the bottom of the foam to the bottom of the valleys. The second thing we need to know is the PEAK HEIGHT of the convoluted. The peak is determine by measuring the distance between the bottom of the valley to the top of the peak.


If you  take the peak and add the base twice you will get your  OVER  ALL THICKNESS of a convoluted set. PU sheets need to be cut to the over all thickness prior to sending them to the convoluter. 






Flash Cutter


The flashcutter is another truly amazing machine. We simply draw a foam part, load its shape into the machine's computer, and the machine cuts everything from that point on. The machine can also determine the best layout to minimize scrap.You can even send us a DXF formatted file with your requested shape and our machine can cut it.This machine is used mostly for prototyping, low volume orders and shapes that require a straight cut edge.It can also cut very large shapes.This saw can cut up to four inches thick, 60" wide and 120" long. Most importantly the Flash cutter makes it simple and fun for us to explore mutiple design possibilities to solve the most challenging packaging problems. 





Die Cutter


When it comes to die-cutting, you will first need to purchase a steel rule die in order to operate the machine.

A die is nothing more than a special shaped blade like a cookie cutter at grandma's house.The press simply

pushes the blade through the foam to produce the shape just like pushing a cookie cutter through dough..

Die cutting is one of the most effecient ways to create a foam shape. Multiple shapes can be grouped together on a indivdual die. This way each hit creates a multiple piece set. Mutiple sets can be produced every minute which makes the die cutter the work horse of foam fabrication.


When foam is cut with a die cutter the machine compresses the foam which forces the cells in the center of the foam outward before the blades cut through the material. After the machine retracks, the foam returns to its original thickness and shape of the die. The foam edges will be concaved. The thicker the material the more concaved the edge will be. This is called CONCAVITY. When samples are produced there is no concavity because the samples are cut with a saw that does not compress the foam. Once the original saw-cut sample is approved the dies are ordered. Once we receive the dies, we create a machine cut sample for approval.Once we receive approval the full job can be run.. See CONCAVITY illustration






Profile Cutter


Our profile machine can cut specialty desiged contour shapes. A pattern is created and followed by a rotating textured wire blade that cuts the shape from the foam. If we made a simple 6" circle pattern and followed it's path, the machine blade would cut the circle shape creating a 6" cylinder that has the length of the block that was placed on the machine. The cylinders are then removed from the foam shaped scrap cocoon and they are moved to a smaller vertical saw where we cut the piece down to the desired thickness and/or length. The scrap is removed from the edges and the profiles are packaged for shipment. 






Multiple PU pads and can be assembled to create protective foam packaging shapes of many different designs. PU parts are easily glued together by using a low temperature hot  melt. This hot melt adhesive is also effective when gluing PU to other foam types and different materials, such as corrugated. 



Would you like us to quote a PU project?  Request a Quote! 

Not the Size You are Looking For?

Not seeing the size you need? No worries, contact us or Request a Quote so that we can custom cut the size you need! 




Contact Information


Technifoam, Inc.

514 Calvary Ave.

Saint Louis, MO 63147



(314) 421-4044


(314) 421-0419


Hours of Operation:

MON-FRI: 7:00 A.M. - 3:30 P.M.







Do you have more questions? Our Operations Manager,  Lisa Niederbrach would love to help you better understand what we do and how we can meet your needs. We are ready to solve your problems with design.  Call or email Lisa today!


Lisa Niederbrach

314-421-4044 (Ext. 11)


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