Flame Lamination

Flame lamination uses heat to bind two materials together, forming a laminated material. At Archbond, we use flame lamination to bond foam to other foam layers as well as fabrics and other materials.

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Flame lamination uses heat to bind two materials together, forming a laminated material. At Archbond, we use flame lamination to bond foam to other foam layers as well as fabrics and other materials.

Flame lamination is ideal for a range of applications and sectors including sports equipment, automotive interiors, industrial manufacturing, bedding, furniture, protective equipment, footwear and more. Flame laminated foam is a popular choice because it offers excellent durability, comfort and manufacturing efficiency.

Archbond has more than 30 years of experience producing flame laminated materials for a range of clients and industries. Whether for large-scale production requirements or one-off prototypes, we can help.

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What is Flame Lamination?

Flame lamination is an adhesive-free method for laminating foam and other materials. A piece of foam is exposed to an open flame, lightly melting the surface and making it sticky. Another piece of foam or material is then placed against the melted surface and pressure is applied. As the melted foam cools and re-solidifies, it forms a bond, holding the other material against it.

In most cases, flame lamination is used to bond polyurethane (PU) foam to fabrics. These foam and fabric laminations are used across a wide range of applications, from vehicle interiors to sports equipment.

The Process:

01 - Material Selection

First, the appropriate foam and facing material are chosen, depending on the end product. PU foam is the most common choice, with the fabric varying by application.

02 - Material Preparation

The foam and the facing material are then checked for quality and condition before being loaded into the laminating machine and aligned.

03 - Foam Surface Heating

The PU foam is passed over a controlled gas flame, slightly melting the outer layer. This creates a tacky surface ready for bonding.

04 - Material Bonding

Almost immediately after heating, the facing material is pressed against the melted surface using rollers. These compress the materials together and ensure a strong, even bond.

05 - Cooling and Stabilisation

The laminated material is then allowed to cool, solidifying the foam and creating a firm bond between the two materials. The bond is strong while allowing the PU foam to retain its flexibility and shock absorption qualities.

06 - Quality Inspection

Each roll of laminated material is inspected for quality. The strength of the bond and the integrity of the materials are checked to ensure a premium finish.

07 - Cutting and Finishing

After being checked, the material can then be cut or trimmed to the required dimensions for the end product.

Materials Used

A wide range of materials are used in flame lamination:

Polyurethane foam
Polyester foam
Polyether foam
PE foam
Fabrics
Films
Textiles
Foils

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Material Versatility

No Adhesive Required

Sustainability

Faster Construction

Multi Layer Capability

Variable Thickness Available

Benefits of Flame Lamination for Businesses

The flame lamination process has a range of benefits, from fast production to reduced environmental impact.

Fast Production Speeds

Flame lamination is quick and straightforward while delivering reliable results, making it ideal for a range of industries and requirements.

Strong Bonding Without Adhesives

Flame lamination doesn’t require any additional adhesives, saving time and money without compromising on strength.

Lightweight and Flexible Composites

The flame lamination process creates a strong bond between materials while retaining the lightweight, flexible qualities of the foam.

Cost-Effective Manufacturing

Because flame lamination is fast and doesn’t use any additional adhesives, it’s a very cost-effective process.

Improved Thermal and Acoustic Insulation

Flame laminated foams and fabrics provide high-grade thermal and acoustic insulation, making them perfect for automotive and construction applications.

Multi-Layer Lamination Capability

Flame lamination services can often handle multiple layers of materials, creating high-performance composites.

Reduced Environmental Impact

Thanks to the lack of adhesive, flame lamination has a reduced environmental impact, not requiring any additional chemicals.

Flame Lamination Applications

Flame lamination creates materials with excellent cushioning, insulation, flexibility, durability and comfort, making it perfect for a wide range of applications.

Automotive Flame Lamination

The automotive industry uses flame laminated materials in a number of ways including: headliners, door panels, dashboards, seating foam and acoustic insulation.

Sports Applications

Flame laminated materials offer outstanding impact protection and thermal insulation, and are perfect for sports applications of all kinds, including: pool covers, sports equipment, saddlery & equestrian and protective padding.

Industrial Uses

There are a number of industrial applications for which flame lamination is ideal, including insulation, protective layers, packaging and flooring underlays.

Why Choose Archbond for Flame Lamination

Since 1985, Archbond has been providing dependable, cost-effective flame lamination services using PU foam. We have full bespoke, in-house production capabilities and are ISO-accredited.

We provide quick turnarounds for all projects with UK-based manufacturing and a wealth of industrial expertise. To discuss your project or learn more, just call our team on 0116 284 1222, email us at sales@archbond.com or fill out our contact form.