At Apollo Foam, we offer foam butt welding services to create sheets exceeding the standard sizes offered by manufacturers. This innovative process utilises heat and pressure to securely bond cross-linked and non-cross linked polyethylene foam, allowing you to achieve the desired dimensions for your project.
- Increased Sheet Size: We can seamlessly join foam pieces, creating sheets up to 1500mm wide and 60mm thick in a single pass. This eliminates the need for sourcing pre-made sheets that may not meet your specific size requirements, potentially saving you time and cost.
- Enhanced Design Flexibility: By overcoming limitations in standard sheet sizes, butt welding unlocks greater design freedom. You can create larger components that wouldn’t be possible with pre-cut pieces, allowing for more intricate and customised projects.
- Clean and Professional Finish: Our state-of-the-art equipment ensures a fast and clean weld with no distortion to the joint surface. This results in a seamless and professional finish that enhances the overall aesthetics of your final product.
- Versatility: We can effectively butt weld various types of polyethylene foam, catering to the diverse needs of different projects.
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.
Again as with the heat laminator no adhesive is required to achieve the desired footprint and thickness.
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.
Foam conversion often involves transforming large foam blocks into smaller pads, resulting in significant material waste. This can hinder project feasibility, especially when the desired finished size is larger than readily available sheets. However, butt welding offers a solution by seamlessly joining smaller pieces into larger sheets, providing several key benefits:
- Reduced Waste
- Cost-Efficient
- Design Freedom
- Competitive Advantage
- Overcoming Yield Challenges
- Versatility