How are seat cushions made?
Moulded foam articles are made one at a time by injecting the foam mixture (isocyanates, polyols, catalysts and additives) into moulds. When the foam rises and expands, it occupies the whole space in the the mould, solidifies and the produced part can then be removed from the mould, either mechanically or manually.
After demoulding, the parts are laid down on conveyors and sent to crushing systems to open the foam’s cells and give it its resilience. After crushing, the parts are sent to quality control and rework. Before being further send to curing, packaging and shipment to customers / integration into car seats.
While the process seems simple, there are many different parameters to consider and it is the art of the foamer to fulfil the complex specifications of car manufacturers to produce the right padding material for the seats.