Six families, one question: what will this layer do?

Density is the weight in kilograms of one cubic metre of foam; 30 density means the foam weighs 30 kg per cubic metre. Density does not determine firmness — it determines load capacity and service life. Soft and firm foam can both be made at the same density. Resistance to compression set under continuous load follows directly from density, which is why density is the value that really decides how many years the product will last.

For a domestic sofa seat, 28–35 kg/m³ is the common range; for heavy-use seating occupied many hours a day, 35–45 kg/m³ is preferred. Back and arm filling can use a lower density, because those areas do not carry continuous load. The final choice depends on the weight of the user and the thickness of the cushion.

A mattress is not built at a single density but in layers. Typical values are 40–60 kg/m³ for the load-bearing base layer, 25–35 kg/m³ for the middle comfort layer and 16–25 kg/m³ for the thin roll layer at the surface. In public-use settings such as hotels, a flame retardant FR recipe is usually required as well.

Roll foam is peeled continuously from a round block, while sheet foam is cut from a rectangular block. The roll method produces almost no offcut waste, which makes it noticeably more economical at thin gauges of 3 to 50 mm. For thicker and dimensioned parts, sheet cutting is the better route.

FR foam is polyurethane foam containing a flame retardant additive, formulated so that ignition and flame spread behave differently. Upholstery used in hotels, hospitals, schools, public transport and government buildings is usually required to have documented fire behaviour. Because the target standard determines the recipe directly, it has to be settled at the very start of the order.

Flame lamination bonds foam to fabric without adhesive, by melting the foam surface with a controlled flame. The melting layer acts as its own adhesive. With no chemical adhesive involved, the bond stays thin and the material keeps its flexibility and breathability. It is the most widely used method in automotive interiors and apparel.

The quantity depends on whether the product is vacuum compressed. Vacuum-pressed roll foam drops sharply in volume, and the square metres carried in the same container rise substantially. This is the single item that most affects unit cost in export; the loading plan is prepared in advance from the dimensions of the order.

Sample requests are accommodated. It is enough to tell us what you manufacture, how the foam has to behave and the target standard if there is one; we then determine the right product family and density range together. Minimum order quantity varies by product type and export destination, so it is shared in response to the specific enquiry.

Polyurethane foam springs back the moment the load is removed. Visco foam softens with body heat, recovers slowly and spreads pressure across the surface. In a mattress the two usually work together: a polyurethane core carries the load, a thin visco layer sits on top. Used alone as the load-bearing layer, visco lets a mattress sag over time, because a viscoelastic formulation is designed to distribute pressure, not to carry weight.

Yes, we manufacture to order. Send us your sample or technical data sheet and we work out an equivalent formulation, then submit a sample for your approval before production. Dimensions, packaging layout and labelling under your own brand are part of our standard practice.

The United Kingdom is the market where our products are used most heavily. The destination also sets the expectation for fire behaviour: in the UK, filling material for upholstered furniture is subject to a separate test under the Furniture and Furnishings (Fire) (Safety) Regulations 1988. Because we prepare the flame-retardant formulation to the target standard, we need to know the country and the application at the start of the order; the loading plan and container fill are worked out from the same information.

One kg/m³ is roughly 0.0624 lb/ft³. Common equivalents: 25 kg/m³ ≈ 1.56 lb/ft³ · 30 ≈ 1.87 · 35 ≈ 2.18 · 45 ≈ 2.81 · 60 ≈ 3.75 lb/ft³. Buyers in the UK and the United States quote density in lb/ft³ and thickness in inches. We state both units in every quotation — this conversion is where supplier comparisons most often go wrong.

Polyurethane foam yellows at the surface when exposed to light and air. This is expected chemical behaviour. It does not change the load-bearing capacity, the firmness or the service life of the foam, and it is not visible on surfaces that sit under a cover. Additives that slow yellowing are available. For products that will sit under a light-coloured or thin fabric, discuss this before the order.