Polyurethane foam is manufactured in so-called long blocks which, cut into short blocks at the next stage, form the basis for further processing. Short sides of the polyurethane foam are then processed, mainly by mechanical cutting on appropriate cutting machines. Depending on the cutting technique, the products are obtained in form of boards (of any thickness), wound boards and profile boards. During the next stage, the boards can be processed into shapes or laminates.

Boards

Boards are made by cutting short blocks into foam sheets of any thickness. Their length and width depend on the short block’s dimension. The board thickness (of 2 mm minimum) is customised. A unit of sale is the number of boards obtained by cutting one short block.

Wound boards

Wound boards consist of the foam wound axially, of thickness from 2 mm to 90 mm. A unit of sale is a foam roll on the minimum length resulting from cutting a layer of a long block.

Profile boards

 A profile board is understood as the foam processed with a profile or a contour machine which gives the foam a texture of lumps, waves, cones, pyramids, etc. The profile boards, usually used in the packages branch, are made by cutting in half the foam board pressed with a profiling shaft. This method always gives two profile boards at one operation. In this case a unit of sale is a pair of boards. The notion “profile” related to the foam texture is understood as the higher to lower height ratio (H to h). The profile layout should be 2/1, which guarantees keeping the shape and quality.

Shapes

Eurofoam Polska owns a stock of machine tools which enables manufacturing shapes in various technologies.
– Shapes extruded at a single level. These are products obtained as a result of processing the foam boards on a hydraulic press using a wooden-board template with cutting knives placed in it. Cutting is made on computer-controlled contour machines, vertical machines or a cutting plotter.
– Shapes extruded at many levels. These are products obtained as a result of processing the foam on a milling machine or on a compressing machine, using a multi-level wooden board template.

Laminates

Laminates are multi-layer materials in which another material is glued to the foam, e.g. polyethylene foam, textile material, film or paper. The laminates are made on a continuous press where the laminate elements are connected using glue, temperature and pressing. Within this technology, it is also possible to apply a glue layer with silicone paper onto the foam.