Layering allows for more precise and accurate cuts. Depending on the method of cutting the individual layers of the foam, the edges can be quite clean without the need for additional finishing.
Layering can be used with a wide range of materials, including expanded polystyrene (Styrofoam), polystyrene, polyethylene, and polyurethane foams. It is particularly well-suited for cutting foam materials used in packaging.
Layering is a fast and efficient process, especially when we use our automated foam bonding equipment allowing for high-volume production with minimal setup time. Once the bonding parameters are established, the process can be automated for consistent results.
Compared to routing, layering foam is less expensive.
The laminating of foam by heat bonding or gluing increases costs. Sometimes designs can be made that eliminate the need for adhering to the foam.
If custom dies for die cutting are required, this can be expensive, especially for complex or intricate designs. The initial investment in tooling may be prohibitive for small production runs.
