BFF Foam Corp. has an incredible array of specialty machinery and technology – combined with the expertise from a team of dedicated, highly experienced staff – that allows us to create foam products that will meet the unique and exact needs of each customer. For every potential application and specification, BFF Foam Corp. has the technology and know-how to produce it.
Because of the unique nature of the technology, many of our machines may not be as well known outside the foam industry. We’ve created a short glossary of descriptions for our customers, to provide a closer look at the unique capabilities of BFF Foam Corp.:
Convoluter
Commonly known as “egg crate” foam, this is the machine that creates it. But this technology goes far beyond the basics: we can take almost any type and shape of foam and convolute it for the exact needs of an individual customer, including specialty packaging materials. We can also create multi-zone, “pin” or waffle convolute, as required.
CNC Contour Cutters
BFF has two of these state-of-the art cutting saws and they’re put to good use creating virtually any two-dimensional shape that can be imagined. “CNC” stands for “computer numerically controlled” foam cutting – patterns can be created from drawings or even photographs imported into our computer system for exact replication.
Surface Modification Technology
This machine allows us to cut multiple heights and design shapes into a single piece of foam. Originally created for the automotive industry, BFF uses the SMT to help provide specific product requirements for our customers.
Die-cutting
Like an oversized cookie cutter, this machine – a travelling-head 50-ton press – can cut out those shapes that require a “cookie cutter” type of production. The machine, using a shaped “die”, can cut out open and closed cell foam and even fabrics, as needed.
Custom Sewing
With years of custom sewing experience, BFF Foam Corp.’s sewing department staff produce everything from mattress covers to exercise mats – and hundreds of items in between – to provide our customers with the perfect product.
Embroidery
A highly precise computer-controlled embroidery machine can reproduce a company logo or product identification as required.
Ultrasonic Welding
BFF Foam Corp. is able to weld different types of fabric together, to create material that is more fluid resistant and pest resistant than ever before. Aside from improving moisture blocking, the ultrasonic welding can help create a product with a better aesthetic than a comparable sewn product.
Custom Mattress Manufacturing
Building to our customers’ specific needs is what we specialize in – with our specialty sewing equipment and ability to laminate various foam types to create comfort layers, BFF can build specialty foam mattress products in latex or polyurethane foam.
