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Open Cell Foam Manufacturer
Open-cell foam is created during the production process as reactions caused by the blowing agent create pockets of gas which expand and ‘open’ the foam. With polyurethane foam, this can be as simple as adding water into the production process, which reacts with one of the polymer composites in the material to create expanding pockets of carbon dioxide.
Even if the foam is not entirely expanded, it is still considered to be open-cell if more than half of the cells are open. This helps to distinguish it from the more dense and durable closed-cell foam.
With a typical density of 15kg/m3 to 150kg/m3, the comparative lightness makes open-cell foam ideal for a range of applications, from protective packaging to cleaning products and furniture.
- Soundproofing – including sound insulation for homes and offices. Acoustic absorption, anechoic wedges, anti-rattle strips.
- Packaging – foam inserts and other packaging for transport or storage.
- Insulation – foam insulation solutions in cases where air flow is required.
- Cleaning – domestic and janitorial, sponges, wipes and mops.
- Medical – cleaning, applicators, wound dressings.
- Car Care – car detailing, polish applicators, sponges ,and compounding pads.
- Sealing – under compression as dust seals.
What We Offer
As specialists in the foam manufacturing process and with a deep understanding of the range of possible applications for open-cell foam, our in-house team of technical foam experts, based in the UK, is committed to providing the ideal solution for your needs.
Whether open-cell foam sheets are required for packaging, case inserts, acoustic and thermal insulation, cleaning or other needs, we can provide a custom solution that ticks every box and will work with you to identify the grades, compositions and thicknesses best suited to your project.
Why choose us?
High-quality, high-tech solutions with no-nonsense guidance, competitive pricing and 100% customer satisfaction.
Foam design and development
We’re not just manufacturers – we offer support and guidance with bespoke foam design and development.
Expertise in foam materials
We have an outstanding reputation in the field of specialist foam and can recommend the right solutions to meet your needs.
How is open-cell foam made?
Open-cell foam is manufactured in a similar way to polyurethane foam, but agents are added during the process to create gas pockets in the material. These open cells reduce the material’s density, making open-cell foam a lightweight, durable material for padding, packaging and insulation.
What’s the difference between open-cell foam and closed cell foam?
Open-cell foam is softer and has more flexibility, allowing it to be compressed and return to its original shape, like a sponge or seat cushion. In contrast, closed-cell foam is much firmer and has a greater density, resisting compression.
While both are durable, the added flexibility of the open-cell structure will cause the cells to gradually break down after extended long-term use. We’ve also created a more detailed guide to the differences between open-cell and closed-cell foams, so take a look there for more details.
Is open-cell-foam waterproof?
No. Open-cell foam is not waterproof but polyether foams are considered to be water-resistant. While closed-cell foam can be water-resistant, only high-density closed cell foams are considered to be waterproof.
What should I use open-cell foam for?
Due to its resilience and ability to resist compression and return to its original shape, open-cell foam is commonly used for car seats, domestic furniture and mattresses, alongside being popular for packaging items for storage or transportation.
In addition, the open-cell structure also means that it is also commonly used in filtration, soundproofing for rooms and some forms of insulation.