What we do
Our Capabilities
150+ years of industry experience has allowed us to develop an advanced skillset when it comes to foam conversion. To find out more get in touch with us to find out how we can help when it comes to your business.
Our Processes
Foam Manufacturing, Conversion & Supply
Foam Manufacturing, Conversion and Supply
We use the very latest state-of-the-art processing machinery for the manufacturing, conversion and supply of polyethylene foam to ensure every product is manufactured cost-effectively and to the highest quality standards.
Ramfoam Expertise is driven by over 150+ years of industry experience, the drive to push boundaries of Polyethylene & Polyurethane foams conversion. Its continuous re investment in state-of-the-art machinery, investments in leading cutting-edge software along with superior in-house training and development of all employees keeping Ramfoam at the forefront of its industry globally.
Splitting & Cutting
The horizontal slitting machines are generally able to process blocks of flexible foam and sponge, both open and closed cell and produce sheets at the required thickness.
This is the foundation of anything that we produces. This is where we take raw material and prime it ready for conversion.
This is used in every sector that we work with.
Laminating
The heat laminating machines utilize heat plates to melt two Polyethylene sheets surfaces together this then produces the customers desired thickness.
This is used to create thicknesses but also create the desired aesthetic look from a colour selection. Laminating is a vital part of the production process allowing us to create products to align with a project goal and can also tie in with a clients brand.
This is a foundation of foam conversion and allows us to prep raw material ready to be used in projects.
Lamination is bonded by heat meaning that there is no need for additional adhesives, because the lamination method uses its raw material to bond it means that as this stage the product is still recyclable if applicable.
Laminating
The heat laminating machines utilise heat plates to melt two Polyethylene sheets surfaces together this then produces the customer’s desired thickness.
This is used to create thicknesses but also create the desired aesthetic look from a colour selection. Laminating is a vital part of the production process allowing us to create products to align with a project goal and can also tie in with a client’s brand.
This is a foundation of foam conversion and allows us to prep raw material ready to be used in projects.
Lamination is bonded by heat meaning that there is no need for additional adhesives, because the lamination method uses its raw material to bond it means that at this stage the product is still recyclable if applicable.
Foam Saw
The vertical cutting foam saw, purpose is to vertically cut all angled and shaped products to the desired thickness and length.
Foam saw is a vertical cutting process that allows the trimming of the foam sheets to create desired pads and blocks and prep them for the finishing procedure.
The foam saw is also a fundamental part of the pre conversion process allowing a clean cut meaning that the foam is primed for butt welding or futher CNC manufacturing on larger projects.
Adhesive Coating
An adhesive application is applied to the foam to allow for easy bonding to textured services.
A combination of heat and pressure is used to apply a layer of adhesive to material. The adhesive can be applied to either foam sheets or thinner material and is then transferred to a roll. Adhesive coating is an effective way of assembling larger finished products without the need for any additional adhesive, it reduces the project timeline allowing for a faster production time.
Adhesive coating is often in sectors such as Construction, Engineering, Aerospace and Automotive but can be used in multiple other sectors aswell.
Adhesive Coating
An adhesive application is applied to the foam to allow for easy bonding to textured services.
A combination of heat and pressure is used to apply a layer of adhesive to material. The adhesive can be applied to either foam sheets or thinner material and is then transferred to a roll. Adhesive coating is an effective way of assembling larger finished products without the need for any additional adhesive, it reduces the project timeline allowing for a faster production time.
Adhesive coating is often in sectors such as Construction, Engineering, Aerospace and Automotive but can be used in multiple other sectors aswell.
CNC Routing Milling
Ramfoam is a market leader in CNC routing/ Milling Technologies, with several state-of-the-art machines with 2d & 3d cutting capabilities.
The fundamental principle of CNC routing and milling is to remove material from a larger parent material. This is done by precision CNC routing that is numerically controlled.
Once raw material has been prepped we can utilise CNC technology to cut precise shapes into the foam for the most premium level of packaging and protection. The majority of sectors that we work with will utilise CNC technology to ensure the products that they are housing are entirely protected.
These products can range from protective cases used for transportation for the aerospace market to aids for the healthcare sector and much more.
Log Cutting
This allows the creation of coils, developed from large rolls of foam.
Log cutting takes rolled material which has usually been adhesive backed and makes precise incisions from a blade which then creates large foam coils.
These can then have a multitude of uses such as gaskets for construction and engineering sectors or can be further developed by other pressing methods to develop smaller foam products that can be used in FMCG markets such as industrial sectors and household goods.
Log Cutting
This allows the creation of coils, developed from large rolls of foam.
Log cutting takes rolled material which has usually been adhesive backed and makes precise incisions from a blade which then creates large foam coils.
These can then have a multitude of uses such as gaskets for construction and engineering sectors or can be further developed by other pressing methods to develop smaller foam products that can be used in FMCG markets such as industrial sectors and household goods.
Water Jet Cutting
Water jet cutting utilises high pressure water to allow precison and complex cuts to be made to a wide variety of materials. The water jet is used to manufacture small or large products for a range of markets where the technicality of the shapes required may not be capable for CNC routing.
Water jet cutting is a valuable tool when it comes to developing products that have an intricate structure that are used in sectors such as the military, packaging and automotive.
Oscillating Flash Knife
The oscillating flash knife uses a precision sharp blade to allow for the cutting of custom shapes and sizes. This is used for a variety of products but is used in most cases of retail packaging and the production of housing and display structures in FMCG markets.
Oscillating Flash Knife
The oscillating flash knife uses a precision sharp blade to allow for the cutting of custom shapes and sizes. This is used for a variety of products but is used in most cases of retail packaging and the production of housing and display structures in FMCG markets.
Thermoforming
Thermoforming is the process of applying heat and pressure to various types of foam, it allows us to emboss custom designs and textures into the material. This allows customers to make aesthetic changes to products such as floats in the leisure sector used for swimming without the need for additional printing.
It can also be used to apply a patterned texture to pads to allow for grip and haptic feedback for sensory products.
Laser Cutting / Etching
Laser cutting and etching create detailed shapes and designs on foam-converted products. The process involves using a laser to cut or etch the foam.
Laser cutting is the process of using laser-generated heat to cut through the material, while etching is the process of using laser-generated heat to etch a design onto the material. This process is precise, fast, and clean, and can be used to create intricate designs with ease. It is commonly used in industries such as automotive, aerospace, and packaging, where precise shapes and designs are needed.
Laser Cutting / Etching
Laser cutting and etching create detailed shapes and designs on foam-converted products. The process involves using a laser to cut or etch the foam.
Laser cutting is the process of using laser-generated heat to cut through the material, while etching is the process of using laser-generated heat to etch a design onto the material. This process is precise, fast, and clean, and can be used to create intricate designs with ease. It is commonly used in industries such as automotive, aerospace, and packaging, where precise shapes and designs are needed.
Fast Welding
Fast welding is an automatic welding process using heat to weld layers of foam with a precision stacking method that allows a larger structure to be fabricated allowing the welding of a complete surface. This allows us to streamline and improve the production time when it comes to more substantial products.
Pressing & Die Cutting
We have one of the largest pressing capacities in Europe. Press and Die cutting allows us to cut multiple types of material to custom sizes and shapes. We use these tools to apply pressure and cut our shapes and layers from the sheet material, this is a perfect process for high volume precision cutting and large manufacturing products.
Pressing & Die Cutting
We have one of the largest pressing capacities in Europe. Press and Die cutting allows us to cut multiple types of material to custom sizes and shapes. We use these tools to apply pressure and cut our shapes and layers from the sheet material, this is a perfect process for high volume precision cutting and large manufacturing products.
CAD 3D Modelling
CAD (Computer Aided Design) is the first pillar of our product development. We utilise cutting-edge software to allow us to design and render complex solutions developed for our clients.
Our in house design team have a wealth of knowledge and experience between them allowing for creativity and collaboration when it comes to developing products for any size and scale.
Butt Welding
Butt welding foam is a specialised welding process that combines two foam pieces. This process creates strong, airtight bonds between two foam pieces, creating a single, solid work.
Butt welding foam is a great way to join foam pieces without additional adhesives or other materials.
Butt Welding
Butt welding foam is a specialised welding process that combines two foam pieces. This process creates strong, airtight bonds between two foam pieces, creating a single, solid work.
Butt welding foam is a great way to join foam pieces without additional adhesives or other materials.
Hand Fabrication
A highly detailed finishing process that allows for intricate and technical fabrication under the watchful eye of our engineers. We utilise hand welding to support the need for large and complex scale projects which cannot be automated.
Our engineers have years of experience working on complex products for clients in various sectors; this process is fed by all of our CNC procedures and finished by hand.
