Rigid Foam for Larger-than-Life Designs

When you think foam, many don’t consider the possibilities of rigid foam in their projects. Even fewer are familiar with the possibilities of low-density rigid foam. 

Our low-density rigid foam formulation is perfect for large contoured and complicated components. We can mould-in (encapsulate) anchors, supports, staple surfaces, and even furniture components like swivel cylinder receivers directly into the low-density part.

Getting the contours consistently correct on a design like the one below can only be done by moulding. We moulded wood inserts in for anchors, attachments, and stapling. The comfort is built into the shape of the LD Rigid Foam part and then the part is completed for upholstery with a thin layer of cut foam glued to the surface of the rigid foam part.

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This example also includes a shape that would be nearly impossible without moulding but also adds the need for a swivel cylinder embedded directly into the rounded bottom. 

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