Flame Lamination

Flame lamination is one of the best, most efficient ways of bonding materials, such as fabrics and foams. It creates a reliable bond, free from the failure points experienced when using traditional adhesives.

We offer bespoke flame lamination services for a range of industries, including automotive, medical, clothing, acoustic products, sports equipment and much more. Speak to Archbond today to find out how our flame lamination services can help you.


UK's Premier Flame Lamination Specialists

Total end-to-end solution through our complete in-house manufacturing service

What is Flame Lamination and Its Benefits?

Flame lamination is a process used to bond dissimilar materials without the need for adhesives. It involves applying flame to the surface of a soft material, typically polyurethane foam, in order to slightly melt the surface and create a thin polymer layer.

The two or more materials to be bonded are then compressed together and the polymer layer cools and solidifies, binding the surfaces together.

The flame lamination process offers a number of key advantages compared to traditional adhesive methods:

  • Material Versatility
    In flame lamination, foam is usually the core material of choice, as it melts easily and forms a strong polymer layer. However, any flame-laminable core material can be attached to a huge range of other surfaces, including fabrics, films, paper and more.
  • No Adhesive Required
    Traditional adhesive bonding methods come with a list of inherent flaws, including failure points and adhesive creep. Flame lamination forms a strong bond, free from these issues, and without the need for an additional, single-use product.
  • Sustainability
    The use of adhesives makes recycling products harder, as the adhesive must be removed before recycling can take place. However, flame laminated products don’t need adhesive and are more recyclable, and require fewer materials to make.
  • Faster Construction
    Flame lamination is usually a quicker process than other lamination options and creates a quicker, stronger bond.
  • Multi-Layer Capability: Flame lamination can be used to bind multiple layers together, and the core material can be melted on both sides for adhesion on each.
  • Variable Thickness
    Your laminations can be a range of thicknesses up to .75 inches, as only very thin layers of foam are needed to create adhesion.

Our Flame Lamination Process

At Archbond, we use state-of-the-art flame lamination equipment to create bespoke laminations in a range of sizes and thicknesses to suit almost any application. As with all our products, our flame laminations are subjected to rigorous quality control measures.

We employ a proven three-stage flame lamination process:

The materials to be flame laminated are selected, inspected and cut to size, ready for lamination.

Once prepared, the materials are fed through our advanced lamination equipment. The surface of the foam is melted to create a tacky polymer layer, and the materials are compressed together to form a bond.

Quality Control
Before our flame laminations are passed to our customers, they’re inspected for quality, ensuring thorough adhesion has taken place and the final product matches our high standards.

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Material Versatility

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No Adhesive Required

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Faster Construction

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Multi Layer Capability

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Variable Thickness Available

Why Choose Our Flame Lamination Services?

At Archbond, we specialise in foam lamination processes of all kinds and operate a suite of cutting-edge lamination equipment to provide bespoke laminations for a huge range of clients from various industries. As with all of our laminations, our flame laminations are unmatched in their quality and versatility.

Contact the flame lamination experts today to discuss your project requirements.

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Frequently Asked Questions

The main materials used in flame lamination are foam made of polyester, polyethene, polyether as well as various other foils, papers and textile materials.

Flame laminating machines are used to join thermoplastic materials together, including foam made of polyester, polyether, polyethene or various adhesive foils and textile.

Flame lamination has a variety of uses suited for different industries. Here are some of the industries they are used in frequently:

  • Luggage
  • Car interiors
  • Packaging
  • Medical disposables
  • Intimate wear
  • Orthopaedic padding
  • Costumes
  • Laminates
  • Beverage insulating
  • Thermal/acoustic insulation


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