Apollo Foam provides innovative, custom engineered polyethylene foam solutions globally

Foam Butt Welding

Polyethylene foam is manufactured in many differing sheet sizes and thicknesses, but what happens when the size of foam you require is bigger than the manufactured size? Or the yield for your item is not conducive with the manufacturers block size? The blocks then need to be butt welded to create the footprint you require.

A butt welder machine
Two hexagon icons

Our sales team have an extensive and unparalleled knowledge

Apollo Foam has the capabilities to butt weld both cross-linked polyethylene and non-cross linked polyethylene to a greater sheet size than produced by the manufacturer of the foam.

We can weld up to 1500mm wide and up to 60mm thick in one pass (This can then be heat laminated to a greater thickness if required). The butt welding machine produces a fast and clean weld with no distortion to the joint surface.

Firstly, the material to be processed needs to be fully trimmed and any manufacturing skin removed to aid with the bond between the two sheets of material. The butt welder clamps the two sheets of material in place by compressing the edges together.

An electrically heated blade then traverses the length of the join, welding the two sheets together to form a length of material governed by the customers requirements, the weld is equivalent in strength to that of the individual sheet.

An electrically heated blade then traverses the length of the join welding the two sheets together to form a length of material governed by the operator, the weld is equivalent in strength to that of the individual sheet.

Again as with the heat laminator no adhesive is required to achieve the desired footprint and thickness.

A very high percentage of polyethylene foam is cut back into a pad before processing into the finished item for the customer. Dependant upon the finished size which is required the yield of the foam in question may make the project a non starter, however being able to butt weld the sheets into a greater or smaller footprint gives the customers options when providing quotations which gives you a key advantage over the competition.

Apollo Foam provide cost-effective polyethylene foam solutions

Our polyethylene foams are converted to our customers’ individual requirements from split sheets, pressed foam fitments, waterjet and routed polyethylene foam components for all market sectors.

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