Our Capabilities

150+ years of industry experience has allowed us to develop an advanced skillset for 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

We use the latest state-of-the-art processing machinery to manufacture, convert and supply polyethylene foam to ensure every product is manufactured cost-effectively and to the highest quality standards.
 
Our expertise is driven by over 150+ years of industry experience and the drive to push the boundaries of Polyethylene and Polyurethane foam conversion.
 
Our continuous re-investment in state-of-the-art machinery, investments in leading cutting-edge software, and superior in-house training and development of all employees keep us at the forefront of our global industry.

Splitting & Cutting

The horizontal slitting machines can generally process blocks of flexible foam and sponge, both open and closed cell, producing sheets at the required thickness.

This is the foundation of anything that we produce. 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 utilise heat plates to melt two polyethylene sheet surfaces together, producing the customer’s desired thickness.

This is used to create thicknesses and the desired aesthetic look from a colour selection. Laminating is a vital part of the production process, allowing us to create products that align with a project goal and tie in with a client’s brand.

This is a foundation of foam conversion and allows us to prep raw material for 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, the product is still recyclable if applicable at this stage.

Laminating

The heat laminating machines use heat plates to melt two polyethylene sheet surfaces together, producing the desired thickness for the customer.

This creates thicknesses and the desired aesthetic look from a colour selection. Laminating is a vital part of the production process, allowing us to develop products that align with a project goal and tie in with a client’s brand.

This foundation of foam conversion allows us to prep raw materials for 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.

The 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, allowing easy bonding to textured services.

A combination of heat and pressure is used to apply a layer of adhesive to the 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 as well.

Adhesive Coating

An adhesive application is applied to the foam, allowing easy bonding to textured services.

A combination of heat and pressure is used to apply a layer of adhesive to the 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 as well.

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 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

Foam Log Cutting allows the creation of coils developed from large foam rolls.

The process 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 many 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

Foam Log Cutting allows the creation of coils developed from large foam rolls.

The process 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 many 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 uses high-pressure water to make precise and complex cuts to various foam 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 of CNC routing.

Water jet cutting is a valuable tool for developing products with intricate structures that are used in sectors such as the military, packaging and automotive.

Oscillating Flash Knife

The oscillating flash knife is designed with a finely sharpened blade that facilitates the seamless creation of custom shapes and sizes. This cutting-edge tool is a game-changer across diverse industries, offering unparalleled accuracy and efficiency in manufacturing processes.

Primarily employed in retail packaging, the oscillating flash knife is instrumental in crafting bespoke designs and dimensions, ensuring each product stands out with immaculate precision. Beyond packaging, it plays a pivotal role in the production of housing and display structures within the fast-moving consumer goods (FMCG) markets, enabling the creation of captivating and sturdy showcases that elevate product visibility and consumer engagement.

Oscillating Flash Knife

The oscillating flash knife is designed with a finely sharpened blade that facilitates the seamless creation of custom shapes and sizes. This cutting-edge tool is a game-changer across diverse industries, offering unparalleled accuracy and efficiency in manufacturing processes.

Primarily employed in retail packaging, the oscillating flash knife is instrumental in crafting bespoke designs and dimensions, ensuring each product stands out with immaculate precision. Beyond packaging, it plays a pivotal role in the production of housing and display structures within the fast-moving consumer goods (FMCG) markets, enabling the creation of captivating and sturdy showcases that elevate product visibility and consumer engagement.

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 will enable 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 apply a patterned texture to pads, allowing 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. At the same time, etching uses 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. At the same time, etching uses 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 will enable us to streamline and improve the production time for 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 has 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 piece.

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 piece.

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.

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