Qingdao Roadzeal Textile Co., Ltd is one of most professional and reliable rebonded foam top manufacturer and supplier in China。
Rebonded foam, often referred to as bonded foam or scrap foam, is an industrial-strength material engineered for durability, shock absorption, and extreme resilience. Unlike standard polyurethane foam which is poured in single blocks, rebonded foam is manufactured by reclaiming high-quality foam offcuts, shredding them into uniform granules, and fusing them under high pressure with specialized polyurethane binders.
The result is a versatile, eco-friendly material that possesses a much higher density than conventional foam, making it the preferred choice for applications requiring structural integrity and long-term performance.
At the core of our manufacturing process is a commitment to “Circular Economy” principles. We utilize advanced mechanical compression technology to ensure that every cubic meter of foam meets rigorous density standards. By precisely controlling the ratio of foam granules to binding agents, we can produce rebonded foam in densities ranging from 60 kg/m³ to over 200 kg/m³.
This high-density structure provides a unique “progressive support” feel. While the surface remains comfortable, the inner core offers a firm foundation that prevents bottoming out—a critical factor for high-traffic seating, medical positioning, and orthopedic bedding.
Our rebonded foam is engineered to serve a wide array of industries, each benefiting from the material’s unique physical properties:
Furniture and Upholstery: Used as the primary core for sofa seats, dining chairs, and office furniture to ensure the cushions maintain their shape for years without sagging.
Orthopedic & Hybrid Mattresses: Rebonded foam serves as the “support engine” in many high-end mattresses. It provides the necessary spinal alignment support that soft foam cannot achieve alone.
Sports and Fitness Gear: From yoga blocks and gym mats to wrestling mats and wall padding, the shock-absorbent nature of this foam protects athletes from impact injuries.
Acoustic and Sound Insulation: Due to its dense, multi-layered composition, it is an excellent material for soundproofing walls, floors, and engine compartments.
Carpet Underlay: Providing a luxurious feel underfoot while extending the lifespan of carpets by absorbing the friction of heavy foot traffic.
When comparing materials for large-scale manufacturing or contract projects, rebonded foam stands out for several reasons:
Unmatched Durability: It is virtually impossible to “break down” rebonded foam through normal use. Its compressed nature means it has already reached a stable state.
Cost-Effectiveness: Because it utilizes reclaimed materials, it offers a premium high-density performance at a fraction of the cost of “virgin” high-resiliency (HR) foams.
Customizable Firmness: We can adjust the compression levels to meet your specific Shore Hardness requirements, ensuring the material is perfectly tuned for your end product.
Environmental Responsibility: Choosing rebonded foam reduces landfill waste and lowers the carbon footprint of your supply chain.
Every batch of our rebonded foam undergoes stringent quality testing. We monitor:
Tensile Strength: Ensuring the foam does not tear under pressure.
Compression Set: Testing the foam’s ability to return to its original thickness after being compressed for long periods.
Air Permeability: Maintaining a level of breathability even at high densities to prevent heat retention in bedding applications.
es. Modern rebonded foam is manufactured using non-toxic, eco-friendly binders. Our products are free from harmful CFCs and meet international safety standards for chemical emissions, making them perfectly safe for mattresses, sofas, and children’s play mats.
Density is the primary indicator of quality. A higher density (e.g., 120 kg/m³+) provides more support and a longer lifespan, making it ideal for gym mats or heavy-duty seating. Lower densities (60–80 kg/m³) are softer and typically used for back cushions or carpet underlays.
Like all new foam products, there may be a slight “new foam” scent initially due to the binding process. However, this is non-toxic and typically dissipates within 24 to 48 hours in a well-ventilated area.
Absolutely. In fact, many of our most popular orthopedic mattresses are “hybrids.” They use a thick core of rebonded foam for support and a top layer of TPE gel, Memory Foam, or Latex for surface pressure relief.
While the foam itself is porous, it can be treated or laminated with waterproof covers (such as PU or PVC) for medical or outdoor use. The dense structure also makes it naturally more resistant to moisture absorption than standard open-cell foams.
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