Our convoluter produces instantly recognizable eggcrate foam from large, horizontally cut sheets, without generating any waste. It is similar to the horizontal saw in principle, by sending a blade through the foam and cutting the sheet into two separate pieces. Instead of making smooth sheets though, the convoluter compresses the foam as it is fed through the machine, using a studded roller to alter areas of pressure during the cut. The cells under the studs are compressed more than the other areas during the cut. When released, the stud-compressed areas form the peaks of the eggcrate foam and areas under less pressure form the valleys.
Our convoluter has an 84 inch wide cutting area, allowing us to cut mattress toppers to any size bedding; one of the machine's most popular uses. The machine feeds automatically, and there is no limit to the length of the original sheet being cut, provided it remains less than 84 inches wide. The height of the foam peaks is adjustable from 1 to 3 inches, as is the thickness of the base; the distance from the bottom of a valley to the bottom of the sheet. Uses for the eggcrate foam include mattress toppers, padding and backing for seating and wheelchairs, insulation, and acoustical foam.
Examples of products fabricated by this machine:
NOTE: Rough edges and markings will be cleaned for any and all finished products.