Intec Foams

0 PRODUCTS/SERVICES
- EMPLOYEES
- YEAR FOUNDED

Intec Foams offer a bespoke, personal, professional and quality foam product development and manufacturing service to all of our clients.

Friendly and experienced advice on both foam selection and engineered solutions to problems, we work as a partnership with our large client base, and carefully selected quality suppliers.


Our ability is being able to take an idea from initial concept through development to full production stage, using our vast knowledge of foams and processing techniques.

 

Products are developed in the most efficient manner available and with  key control parameters to ensure consistency.


For more conventional foam products we have low minimum order quantities and a fast turnaround system. No Job is too small.
 

Our Foams include:

  • Polyurethane foam
  • Polyethylene foam
  • Reticulated foam
  • Neoprene sponge rubber
  • EPDM sponge rubber
  • PVC foam
  • Hydrophilic (Cellulose)  foam
  • EVA foam
  • Melamine foam
  • Closed Cell Foam
  • PE foam extrusions

Many are available in Fire retardant grades BS476 Class 0, UL94 HF1 & V0 and FMVSS 302. There are also grades with Low Smoke Emission and Low Toxicity.
 

Conversion
We  cut, laminate, sew, weld, profile and package foam products specifically to your requirements. Please contact us to discuss your own special foam requirements.

Services

Intec Foams are experts in technical foams and foam product development.
We develop unique and cost effective product solutions to meet your specifications by working alongside specialist partners and using our 25 years of experience to select materials from hundreds of foam types.

Our foam product range includes:

  • Polyurethane (PU) Foam
  • Cellulose Sponge
  • Medical  Foam
  • Polyethylene Foam
  • EVA Foam
  • Filtration Foam
  • Sponge Rubbers
  • Melamine Foam
  • Closed cell foam
  • PVC foam
  • PVC Nitrile (NBR) foam
  • PE foam Extrusions (Tubes, cylindrical, Edge & Corner protectors)

Specialised Foam Cutting

Having a close relationship with our foaming partners, we have a direct route and complete technical support for the development of new foam grades.

With the vast amount of knowledge of how the foams react to cutting technology, we have the ability to create shapes which many others cannot achieve, and have at our disposal state of the art equipment and bespoke equipment and tooling where necessary to achieve a product design.

As well as being able to supply simple sheets and rolls of foams with and without self adhesive backings, we are able to supply foams using the following conversion techniques:

 

  • Log-cuttng
  • Contour cutting
  • Roller production
  • Lamination
  • CNC Die cutting
  • CNC Profiling
  • Routing
  • Waterjet cutting
  • Laser cutting
  • Flash Cutting
  • Kiss cutting
  • Deflection cutting
  • Chamfering
  • HF welding

Our extra capabilities also include:

  • Specialised sewing
  • Flow wrapping/packaging
Specialised Foam Cutting

Medical Case Study

Intec Foams were approached by a "Blue Chip" medical company to help with the development of a foam product for use in a medical device, where the foam came into direct contact with the body both internally and externally.

The foam product needed to be cut to a certain size and shape which was a key to the functionality as was the foam selection. It was established that the foam was to meet ISO 10993 for In-Vitro Cytotoxicity, primary skin irritation and skin sensitisation and that we set up a "laundering" procedure to remove and monitor bio-burden. 

Our experience determined that we chose reticulated foam with good water and chemical resistance, and to develop a bespoke machine for the actual conversion of the foam into the specific design.
Our Engineers developed a machine and process capable of consistent long term manufacture.
We worked with a specialist company in the field of Clean room Laundry, to develop a process which met the client's criteria, plus a manufacturing protocol for each batch processed, so that we limited contamination at the cutting stage. Complete traceability of each batch of foam was included as part of our internal quality assurance systems.
Once the basic specification and prototype samples were approved, we worked with the client by supplying samples for the testing of the foam for approval to ISO 10993 tests.
By using our technical knowledge, innovation and working as part of a team with our client, we successfully developed the product and samples for both trials and medical approvals, in order to get the product to Market.
Find out more about our medical based foam products, click here.

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Closed Cell Foams

Closed Cell Foams
Closed cell foams are created during the foaming process whereby the cell bubbles or gases are completely encapsulated. This renders the foams good for:

  • Seals & Gaskets
  • Floatation
  • Buoyancy
  • Antivibration
  • Noise control (acoustics)
  • Thermal insulation
  • shock absorption (packaging

The types of foam that are classed as closed cell are:

  • Polyethylene Foam
  • EVA Foam
  • Neoprene Sponge Rubber
  • EPDM Sponge Rubber
  • PVC/Nitrile Sponge Rubber (NBR)
  • PVC Foam

Please visit our website for more information.

Neoprene Sponge Rubber

Neoprene Sponge Rubber
Our Neoprene Sponge Rubber is of Excellent Quality and ideal in the presence of oils and high temperatures.
We supply in many different formats, such as

  • Rolls
  • Sheets
  • With or without a self adhesive
  • Coils cut to width
  • Cut into shapes for seals & gaskets
  • Thickness can be cut down to 1.5mm

We do not have a minimum order quantity, and can supply quality products in a short lead time at a competitive price.

Please call us to discuss your particular Neoprene Sponge requirements

Polyethylene Foam

Polyethylene Foam
We have a wide range of cross-linked and non cross-linked closed cell polyethylene foams, varying in density and hardness.

We can supply some grades in rolls, and sheets. We can also apply self adhesive backings as well as cut into shapes.

Extruded polyethylene foams are also available, with a lot of standard tubes and cords, as well as edging strips for packaging. We can also create special profiles so long as the volumes are sufficient.

We can also die cut in shorter lengths to your required profile.

Please call us to discuss your requirement.

PVC Vinyl Foam

PVC Vinyl Foam
A selection of different density PVC  or vinyl foams for many applications, with HF weldability being a key property.

Many different thicknesses are available in standard 1m widths and black colour. Subject to MOQs there are other widths and colours available

Please give us a call to discuss your particular requirements.

EPDM Sponge Rubber

EPDM Sponge Rubber is a closed cell sponge rubber product which makes it ideal for General Purpose sealing applications.

Used where oil resistance isn’t a requirement and in many general gasket/seal outdoor applications due to excellent ozone, UV light resistance, weatherability.

Different grades are available, so please ask us if there is something specific required.

EVA Foam

EVA Foam is a Co-Polymer of Ethylene and Vinyl Acetate.

The foam is closed cell and impervious to liquids. The vinyl acetate gives the foam a more “rubbery”, resilient feel to its Polyethylene foam counterpart at the same density.

It is a polymer that approaches elastomeric materials in softness and flexibility, yet can be processed like other thermoplastics.

Different densities are available.

PE Foam Extrusions

We stock various standard Polyethylene foam extrusions in tubes, cylindrical and edge and corner protectors. We have the facility to cut to size if required and sell by the box. Other shapes/profiles can be developed subject to minimum order quantities

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