Low-density flexible foam, produced as slabstock through continuous or batch-block methods, is a versatile material used in mattresses, furniture cushions, automotive interiors, clothing, and acoustic insulation. Foam blocks are cut to precise sizes or shaped into thin sheets, often laminated to textiles for applications like seat covers, door panels, headliners, or even fashion items like shoulder pads.
Produced in densities from 12–80 kg/m³, foam hardness can vary independently of density, with most Australian production below 22 kg/m³. TDI-based polyether foams are commonly used, while polyester grades serve specialty needs such as peelable thin sheets. Advanced cutting, shaping, and peeling techniques help reduce waste, and off-cuts are frequently recycled into reconstituted chipfoam. The industry also focuses on safety and sustainability, developing fire-resistant CMHR foams and environmentally friendly alternatives to traditional blowing agents. This combination of adaptability, comfort, and efficiency makes flexible foam an essential material across diverse sectors.