The process to die cut foam is a fast, cost-effective way to manufacture high-volume foam components your business uses.
Foam die cutting uses a cutting tool and a press to cut shapes, pockets, and components from foam materials. It provides a highly repeatable manufacturing process that can produce large quantities of identical parts quickly and efficiently. Die cut foam is particularly well-suited to high-volume production, where consistent quality, fast production speeds, and low unit costs are essential.
At Polyformes, we operate multiple die-cutting presses capable of producing foam components in a wide range of sizes and materials. Our production teams use them to manufacture die cut foam packaging, case inserts, protective dunnage, presentation packs, and individual foam components tailored to your business’s specific requirements.
See our die cutting equipment and processes in action at our UK foam conversion site.
The benefits of using die cut foam include:
Foam die cutting is a manufacturing process that uses a custom-made cutting tool, known as a die, to cut shapes from foam sheets. The die is pressed into the material, cutting through it to produce accurate, repeatable parts.
Die cutting is typically the best choice when a design is unlikely to change (due to the initial tooling costs), and large quantities are required. The process offers excellent repeatability and low unit costs, making it ideal for ongoing production runs.
Die cutting and CNC routing are both suited to different applications. Die cutting is generally a more cost-effective process for high-volume production runs than CNC routing. However, CNC routing is often better suited to prototypes, low-volume orders, and complicated 3D shapes. Unlike CNC routing, die cutting cannot produce pockets at specific depths (it cuts through the material fully) unless multiple layers are laminated after cutting. The most suitable process depends on the product design, the material, and the required quantity.
Die cutting is frequently combined with processes such as laminating, laser engraving, waterjet cutting, and CNC routing to create finished foam products that meet specific customer requirements.
Our more than 40 years of experience in foam conversion and die cutting, means we can offer your business several benefits.
UK manufacture
Short lead times
Latest equipment
Advice and guidance
Vast experience
Sustainable at heart
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