Foam Isn’t the ONLY Answer

As much as we sometimes think that our foam can solve all your challenges, there are some cases where a large foam piece isn’t the best or most cost-effective solution. 

We were engaged by a customer that was looking to have arms for a modular sofa moulded. These arms could then be attached in different lengths to create a chair, loveseat, or sofa. This approach would have required two large patterns and two large moulds, one for the right arm and one for the left. We proposed that we only mould the difficult to fabricate part, the corner, and that the flat straight sections for the arms and along the back, be fabricated from plywood and assembled to the rigid foam corners. The rigid foam corner was designed to be ambidextrous, so only one, much smaller pattern and mould were required. The corners are bolted to the straight plywood assemblies by means of a simple steel plate that is inset in the rigid foam and plywood.

This approach of simplifying the production of the most complicated shapes in a design and completing the rest of the assembly using more traditional approaches allows our customers to save on tooling and skilled trades, while leaving most of their production processes as they are. 

We are always thrilled to create parts that make up the majority of a project, but we will also always recommend the best approach that we can based on our years of experience. Even if that means less of our foam in the final product. 

Have a difficult to fabricate project or part that you want to discuss with us.

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