Precision is more than our promise—it’s a process, and our compression cutting capabilities are taking foam customization to the next level. Whether you’re looking for tailored comfort zones in a mattress or bespoke acoustic foam panels for a recording studio, our advanced technology ensures results that are accurate, consistent, and engineered to perform.
What Is Compression Cutting?
Compression cutting is a highly specialized process that allows us to create detailed, repeatable foam patterns that are impossible to replicate by hand. Think of it as a hybrid between a die cutter and a foam convoluter. Here’s how it works:
Using a computer-controlled CNC router, we craft precision templates out of laminated particleboard. The foam is then compressed over this custom mold, and a horizontal blade slices through the material. The result is a mirrored pattern, cut cleanly and consistently, every time. This process enables intricate shapes and contouring on both sides of the foam and is ideal for high-volume or highly customized applications.
Foam Types Compatible with Compression Cutting
Our compression cutter is compatible with nearly all open-cell polyurethane foams, including:
- Memory foam in various densities
- High-resilience and high-density foams
- Charcoal packaging foam
- Outdoor-grade Dryfast foam
This versatility makes compression cutting one of the most powerful tools in modern foam fabrication.
Customized Comfort: Mattresses and Toppers
With sleep science advancing, more people are seeking custom solutions for better rest. Compression cutting allows us to create foam mattresses and toppers with precision-zoned support. Whether you need extra cushioning for pressure points like the hips and shoulders or firmer support beneath the lower back, we can craft a sleep surface tailored to your exact needs.
We also offer laminated foam options for multi-layered mattresses and can accommodate larger bed sizes thanks to our extended cutting table. If you already own a foam mattress and want to enhance its performance, we can modify it using this same advanced technique.
Acoustical Foam: Function Meets Form
In addition to comfort foam, our compression cutter excels in the production of custom acoustical panels. You can select from our in-house patterns—such as Acoustic Grid, Acoustic Spade, and Acoustic Wave—or provide a custom design for repeatable production. Eggcrate, Wedge, and Pyramid styles are also available for traditional soundproofing needs.
Whether you’re outfitting a professional recording studio, a home theater, or a workspace, compression-cut acoustic foam enhances both the aesthetic and acoustic performance of the room.
Turn Your Concept into Reality
Ready to bring your idea to life? Whether you’re starting with raw foam or need modifications to a current product, our compression cutting service delivers the results you need with speed and precision. Contact us today to learn more about custom foam solutions for sleep, sound, or specialty applications.
Do you cut odd sizes for mattress foam ? Such as 30 x 77x 5.
Hi John,
Yes, we absolutely can and do cut custom and irregular sizes for our mattresses and mattress toppers, 30” x 77’ x 5” included. You can even create and order your own directly on our site right here: https://www.foambymail.com/custom-foam-mattresses.html. If you’d like more information about custom mattresses or help selecting the foam type right for you, visit our Contact Us page. Have a great day!
-Foam Factory