Die Cut Foam Photo Courtesy of Thrust Industries.

Foam is not a material often on display because its purpose is usually within an object or system rather then on the outside in a visible position. This is because foam is an excellent shock absorber and vibration absorber, making it the perfect padding for applications such as packaging, cushioning, inserts and insulation. All of these applications can be utilized in a variety of sizes and shapes, which means a production process that is flexible and quick is necessary for creating foam products. Die cutting is the perfect technique for creating varied foam pieces, particularly when being used in mass production settings.

Specific foam products include gaskets, seals, sound dampening pieces, cushion pads for chairs or benches, vibration mounts and insulators, as well as being incorporated into other products as padding or shock absorbers, such as within the lens cover of a camera or built into paper packaging products. Another common use for die cut foam is as sheets of sound absorbers built into the walls of recording studios and other similar environments.

Die cut machines are available for die cut foam product production as well as other materials too, such as metal, wood and plastic. However, the actual die cutters on a machine are often designed for specific materials or at least ones with similar textures and softness levels and such. These tools used to do the actual cutting of foam may vary, although for die cut foam the most popular method is the classic blade cutting method. Ultrasonic cutting and laser cutting involve utilizing heat to separate a specific design from a raw material, which would damage the sensitive foam material. Because foam is so soft and malleable it can be shaped quickly and efficiently, making it a more cost-efficient material to produce then other harder materials.