Foam Cutting

CNC profiling involves using a computer-controlled blade to cut intricate shapes and patterns into a block of foam. It is essential for products requiring specific ergonomic shapes, such as pressure-relieving mattress cores (castellations) or complex packaging inserts, ensuring identical results for every unit.

Yes. Our F&K profiling technology allows us to cut complex, multi-dimensional shapes from a single block. This "nesting" capability often allows us to produce multiple units (like mattress cores) from one block, maximizing material usage and reducing waste.

A band knife is typically used for "blocking up" or preparing raw materials—making straight, clean cuts to size the foam before detailed work. A CNC cutter is programmable and used for the detailed profiling, contouring, and shaping of the final product.

Yes. We provide water-based foam lamination, which allows us to bond different layers of foam together (e.g., a memory foam layer on top of a supportive base foam) to create multi-functional products with specific comfort and support characteristics.

We use water-based adhesives because they are safer, non-toxic, and environmentally friendly. They eliminate the harsh chemical odors associated with solvent-based glues and result in a softer bond line that doesn't create a hard "crust" between foam layers, which is critical for comfort products.

Absolutley. Our equipment is calibrated to handle various densities, including standard PU (polyurethane) foam and technical visco-elastic (memory) foam. We frequently process these materials for the medical and retail bedding markets.

Yes. We have extensive experience manufacturing pressure area care mattresses and patient moving equipment. Our facilities are set up to handle materials that must comply with strict medical device regulations, ensuring hygiene and performance standards are met.

Yes. Beyond medical applications, we manufacture bespoke products for the retail bedding market, including domestic mattresses and pillows. We can work with you to develop specific comfort profiles to differentiate your brand in the consumer market.

We offer a flexible supply model. We can source specific grades of foam through our established supply chain partners, or we can process customer-supplied materials (free issue) depending on your preference and project requirements.

We utilize a specialized foam printing machine that applies identification codes directly onto the foam. This ensures complete batch-to-batch traceability, which is a critical requirement for medical compliance and quality control audits.

Yes. Our in-house design team can take you from "initial concept to production reality." Whether you have a rough sketch or a finished CAD file, we can assist in optimizing the design for our CNC machinery to ensure the most cost-effective production method.

We generally work with vector-based CAD files (such as DXF or DWG). If you do not have these files, our design team can help create them based on your prototypes or specifications.

Yes. Because our CNC machines are programmable, we can run single-unit prototypes or small batches for testing and validation without the need for expensive physical tooling or molds.

Roll packing is the process of compressing a foam mattress or product, rolling it tightly, and vacuum sealing it. We have specific machinery for flat and roll packed finishing, which significantly reduces shipping volume and storage costs for our clients.

No, provided high-quality foam is used and the product is allowed to recover upon opening. Our equipment is designed to compress the product safely to ensure it returns to its original shape and performance levels after unpacking.

We offer a full turnkey solution. In addition to foam cutting, we can manufacture the covers (sewing/welding), insert the foam cores, and pack the finished item. This allows you to receive a shelf-ready product without managing multiple suppliers.

Lead times depend on material availability (if we are sourcing) and the volume of the order. However, our high-speed CNC and automated packing lines allow us to handle large-scale runs efficiently. Please contact sales for a current estimate.

Yes. While we have deep expertise in the medical sector, we apply the same rigorous quality standards to our work in technical textiles, retail bedding, and other industrial applications.

Our foam cutting and fabrication facility is located at our headquarters in Skelmersdale, Lancashire. We service clients across the UK and internationally from this central hub.