Bath Sponge Foam - Technical Foam Services

The client

Leading household beauty brand

The challenge

Our customer had a unique idea.

“In 2007, we invented a new type of bathing sponge, which was to be produced in a specific type of soft polyurethane foam and shaped in a particular style,” he explains. “We approached several UK foam companies, none of whom seemed to be interested in my product, until I spoke to Technical Foam Services.”

He had invented a sponge with a bar of soap inside. As the sponge got wet, so did the soap, which dissolved and filtered through the sponge as a lather. This ingenious invention eradicated the issue of slippery soap, as well as grimy soap dishes.

The challenge

There were three challenges.

The first was determining the right grade of foam with the right cell structure. The soap had to dissolve and filter through the sponge in a controlled way. This latter point was essential, so the sponge didn’t just become a soggy, soapy mess all at once.

The second was how to create a void inside the sponge.

The final challenge was how to get a piece of soap inside a sponge leaving no hole and without using glue or stitches.

Our solution

First, our experts researched, defined and sourced a foam grade that would let the soapy lather pass through in a controlled way.

The second challenge was harder. We worked out a way of inserting a milling tool through a slit in the sponge to hollow it out without damaging the outer structure. We milled the middle of the sponge and then held the hole open so that the excess material from inside could be vacuumed out.

And the third solution involved a clamp with a rope handle, which solved two problems: how to seal the soap inside, and how to store your soapy sponge.

The results

“Technical Foam Services were fantastic right from the outset. As soon as I contacted them, they immediately sent samples of suitable foam grades and gave me expert advice as to what was practical from a foam-converting perspective.

“They were also very useful in terms of general advice with the costing and margins of retail products, as they had been a supplier to Tesco’s for many years.

“Finally, they guided me through the process of retail packaging, which was very helpful. My product is now firmly established in some major retailers, and I am truly grateful for their support.

“I continue to enjoy a fruitful relationship with Technical Foam Services and would certainly recommend them to any other budding inventor of a foam-based product.”