Convoluted foam, also known as egg shaped/wavy shaped foam, is made through a specialized manufacturing process that creates its distinctive wavy, textured surface. The following are the conventional methods for producing this convoluted sponge：
1. Base Foam Production
The process starts with polyurethane (PU) foam or other foam types (like memory foam or rebonded foam).
The foam is then cured and cut into sheets of the desired thickness via a horizontal foam cutting machine.
2. Convoluting
The flat foam sheet is fed into a convoluted foam cutting machine, the blades cut a wave-like pattern and the depth and spacing of the cuts can be adjusted to a deisire one.
The foam is then cut into final sizes.
Why Need to Produce The Convoluted Foam
- Improved Airflow – The peaks and valleys allow better ventilation.
- Pressure Relief – Reduces pressure points by distributing weight evenly.
- Lightweight & Cushioned – Often used in medical, bedding, and packaging industries.
This convoluted foam is widely utilized in various industries, including mattress production, healthcare (e.g., medical padding and support), and protective packaging.