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At Dal-Bac, creating custom foam lamination solutions has always been a big part of our business. The reason is that foams are very versatile materials that can be combined in a wide variety of ways to create solutions to very specific product challenges. While we have worked with cross-linked polyethylene foams, polystyrene foams, vinyl-nitrile sponges, EVA sponges and other expanded polymers and elastomers, our primary focus has always been low density, open-cell polyurethane foams. We work with grades, peeled or skived to a wide range of thicknesses, of polyether or polyester base, clickable or non-clickable, in soft to firm grades and in a range of densities, to meet the performance characteristics that our customers have come to expect of our foam laminates. We specialize in creating custom solutions for our customers and our process for foam lamination projects includes:

  • Understanding the specific needs and characteristics of the final foam lamination product.
  • Recommending the specific materials to be used to meet the specifications. This requires us to understand:
    • Appropriate thickness of the foam or foam core
    • Padding characteristics required
    • Insulation requirements
    • Density requirements
    • Outer layer requirements – fabric, substrate or adhesive
    • Breathabiity and comfort requirements
    • Tensile strength of the composite
    • Functional requirements such as hook and loop components
  • Partnering with our customers and utilizing our ISO 9001:2015 certified processes we have created foam lamination solutions across a wide range of industries

    • Automotive and Trucking
      • Thermal and acoustical insulation composites
      • Soft interior surfaces
    • Advertising Specialty
      • Flexible beverage insulating laminates
    • Medical and orthopedic
      • Orthopedic devices and braces
      • Disposable component materials
      • Padding
    • Sports equipment
      • Specialized composites for comfort and impact protection
        • Batting helmets
        • Saddle pads
        • Gym mats
      • We love challenges, so if you have a need for flexible foam based composites with specialized or unique characteristics, we would like to talk with you.

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