European Foam Conversion Specialists
With extensive expertise in foam conversion, we’re equipped to deliver innovative solutions tailored to your business needs. Get in touch with us to learn how we can support your next project.
Precision Foam Conversion: Tailored Solutions for Every Industry
At Ramfoam, we deliver precision-engineered polyurethane and polyethylene foam products, tailored to meet the unique needs of industries worldwide. Our advanced capabilities include cutting, shaping, laminating, and moulding foam to exact specifications, ensuring high-performance solutions for applications such as aerospace components, automotive insulation, and protective packaging.
With cutting-edge machinery and a skilled in-house design team, we create innovative foam solutions that are both functional and visually striking. From lightweight impact-resistant materials to thermal and acoustic insulation, our expertise ensures reliable results for even the most complex requirements.
Sustainability is central to our process, offering eco-friendly materials and minimising waste. Coupled with fast lead times, extensive stock, and exceptional customer service, Ramfoam is your trusted partner for complete foam conversion solutions, from concept to completion.
Splitting & Cutting
Horizontal slitting machines can generally process blocks of flexible foam and sponge, both open- and closed-cell, producing sheets to 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 use heat plates to melt two polyethylene sheet surfaces together, producing the desired thickness for the customer.
This creates the desired thickness 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. This means that at this stage, the product is still recyclable if applicable.
Foam Saw
The vertical cutting foam saw is used to vertically cut all angled and shaped products to the desired thickness and length.
The Foam Saw is a vertical cutting process that allows trimming foam sheets to create desired pads and blocks and to 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 further CNC manufacturing on larger projects.
Adhesive Coating
An adhesive application is applied to the foam, allowing easy bonding to textured surfaces.
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 used in sectors such as Construction, Engineering, Aerospace, and Automotive, but can also be used in other sectors.
CNC Routing Milling
Ramfoam is a market leader in CNC routing/Milling Technologies, with several state-of-the-art machines featuring 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 the raw material has been prepped, we can utilise CNC technology to cut precise shapes into the foam for the highest level of packaging and protection. The majority of the sectors we work with will utilise CNC technology to ensure the products they house are fully protected.
These products can range from protective cases for transportation in 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.
Water Jet Cutting
Water jet cutting uses high-pressure water to make precise, complex cuts in 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 suitable for CNC routing.
Water jet cutting is a valuable tool for developing products with intricate structures used in sectors such as the military, packaging, and automotive.
Precision Digital Cutting
Need precision-cut materials with flawless accuracy and fast turnaround times? Our Zünd G3 L-3200 digital cutter delivers just that. Engineered for versatility, it handles a wide range of materials with razor-sharp precision, whether for one-off prototypes or high-volume production.
Equipped with both knife and router modules, it offers exceptional flexibility, cutting up to 110mm deep with a beam clearance of 120mm. That means cleaner cuts, tighter tolerances, and faster production—helping you bring your designs to life with zero compromises on quality.
Looking for a cutting solution that meets your exact specifications? Let’s make it happen.
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 a laser to generate heat to cut through 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 process that uses heat to weld layers of foam with a precision stacking method, enabling the fabrication of larger structures and 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 out shapes and layers from sheet material; this is a perfect process for high-volume precision cutting and large-scale manufacturing.
CAD 3D Modelling
CAD (Computer Aided Design) is the first pillar of our product development. We utilise cutting-edge software to design and render complex solutions for our clients.
Our in-house design team has a wealth of knowledge and experience, enabling creativity and collaboration when developing products of any size or 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.
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.