What is Foam Lamination?

Foam lamination is a necessary step in the production of foam composites as it allows two types of materials to be merged into one element.

It’s an effective procedure for bonding foam to materials such as glue, cloth, film, foil, foam itself and others, and hot melt, flame and infrared lamination are the three most common processes (heat lamination).

Foam lamination is a common process in multiple industries, including automotive, packaging solutions, footwear comfort, sports gear and protective clothing, furniture, childcare products and more. Explore our information page to discover how it all works.



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What are the Benefits of Foam Lamination

Foam lamination offers several benefits over other bonding methods, like gluing, welding or stitching. Including the following:

  • Improved comfort: Foam lamination provides a comfortable and soft surface for users, making it an ideal choice for products such as footwear, clothing and sports equipment.
  • Enhanced durability: Foam lamination improves the strength of a product by creating a bond that evenly distributes and pressure, whilst preventing tearing or ripping.
  • Improved safety: Foam lamination provides further safety features by establishing a barrier that prevents penetration or puncture, commonly used in protective gear or medical devices.

Why Choose Our Foam Lamination

Over the last 20 years, our abilities and knowledge have expanded into additional industries, giving us the ability to design and laminate many different products, including floor underlay, automotive textiles, sport and leisure equipment, apparel, luggage goods and more.

Get in touch to discuss your foam lamination needs with an expert member of our team.

Features of Foam Lamination

Foam lamination can be used with a variety of foam materials. This makes it a popular choice for many industries as the versatile bonding method suits many different applications.

For added comfort, foam lamination is perfect, providing a soft and comfortable surface for users, making it an ideal choice for products that touch the skin.

Foam lamination can provide thermal and acoustic insulation, which makes it perfect for products that require temperature control or noise reduction, such as camping gear or automotive components.

Foam laminating enhances the strength of a product by establishing a robust bond that distributes stress and prevents tearing or ripping.

Laminated foam fabric is also a lightweight solution, which is important for products that require a low weight-to-strength ratio, like automotive interiors and aerospace components.

infrared foam lamination

Applications of Foam Lamination

sportswear and equipment 2 (hiking)

Automotive industry
Foam laminating is used heavily in the automotive industry, for interior designs, noise reduction, thermal insulations, as well as improved aesthetics.

Medical industry
Foam lamination is used in medical devices, such as braces and prosthetics, for added comfort and support.

Footwear industry
Laminated foam fabric is used in the assembly of footwear, providing added support, cushioning and comfort. It is also used to create waterproof and breathable barriers.

Aerospace industry
Foam lamination is used in the production of aircraft interiors, thanks to its strong yet lightweight properties to provide added comfort and noise reduction.

Sports industry
Foam laminating is used in the production of sports equipment, such as padding and specialist gear, for improved shock absorption and protection.

Construction industry
Foam lamination is used in the production of materials for thermal and acoustic insulation. It is also used in the process of creating roofing materials.

The Foam Lamination Process

Foam lamination is used in a variety of industries, for an array of purposes. From packaging and construction to medical cushioning and transportation. This versatile material boasts numerous advantages that make foam lamination a popular process.

Put simply, foam lamination consists of a foam material which is bonded to either additional foam or other materials. There are numerous ways of producing foam lamination, each of which is beneficial.

The Three Types of Foam Lamination

Foam lamination is a process that involves bonding foam materials together to create a composite structure with enhanced properties. This technique is widely used in various industries, including automotive, aerospace, sports and medical manufacturing.

Hot Melt Adhesive Lamination

At Archbond, we use Pur Hot Melt Adhesives. This is so we can produce both glossy and matte laminated foam materials. One of the major advantages of Pur Hot Melt Lamination, is the end material can be created quickly, as it solidifies as soon as the industrial adhesive has cooled.

Whether you’re looking to create large surface products like mattresses or need a stronger foam material for use in HVAC systems, hot melt lamination is the ideal solution for you.

Flame Lamination

Flame lamination is another type of thermal lamination process. Unlike hot melt lamination, which requires the use of a separate adhesive, flame lamination can be carried out using the substrates to be bonded. One of the main advantages of flame lamination, is that is does not require any adhesive.

The process tends to work best when bonding flexible layers of foam to non-woven fabrics, but it’s also ideal for bonding foam to paper-based products and films.

Infrared Lamination

The infrared lamination process is similar to the flame lamination, as it doesn’t require any adhesive. Its therefore another cost-effective, sustainable solution for creating your ideal composite materials. The infrared lamination process is ideal for creating a stable bond between different substrates of materials.

It creates incredibly durable laminated-foam-based products, which are highly protective, making them ideal for use in a variety of industrial uses, including the automotive sector.

PU vs PE Foam

The two most common types of laminated foam are PE (polyethylene) and PU (polyurethane). Both materials prove incredibly useful when it comes to enhancing performance, but PU foam tends to be thicker and softer, providing greater cushioning properties.

Conversely, PE foam triumphs if you’re looking for a firm foam composite material for use in flooring, shock-absorbing mats and more.

Have a Question? Get in Touch!

Don’t hesitate to ask us for information or advice.
You can e-mail us directly at sales@archbond.com or call us on 0116 284 1222.

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