Also known as: Bonded Foam, Chipfoam, Re-bonded PU Foam
Rebonded foam is made by shredding polyurethane offcuts and bonding the chips under pressure into a dense block. It is firmer and heavier than virgin PU foam, costs less, and is used where load-bearing firmness matters more than surface finish.
Rebonded foam turns what would be scrap into a usable material. PU trim from fitment cutting is shredded, mixed with a binder and compressed into large blocks, which are then sliced to thickness. Density is controlled by how hard the chips are compressed.
The resulting material is noticeably firmer than the virgin foam it came from, and considerably denser — commonly 80–200 kg/m³ against 16–40 for standard PU. That firmness makes it good at carrying load without collapsing, which is why it is common in gym flooring, mattress cores and heavy-duty packaging bases.
Its visible characteristic is the mottled, multi-coloured chip appearance, which rules it out of any application where the foam is seen by an end customer. In packaging it is used as a structural base layer under a cosmetically acceptable top layer.
For packaging specifically, rebonded foam is a good answer to heavy static loads and a poor answer to impact. It is stiff enough that a dropped load decelerates abruptly rather than over cushioning travel, so it is usually paired with a softer top layer.
Rebonded Foam at a glance
| Made from | Shredded and re-bonded PU foam offcuts |
|---|---|
| Typical density | 80–200 kg/m³ |
| Firmness | High — considerably firmer than virgin PU |
| Appearance | Mottled multi-colour chip structure |
| Sustainability | Uses production scrap that would otherwise be waste |
| Best suited to | Load-bearing bases and structural layers |
Common questions
What is the difference between rebonded foam and memory foam?
Rebonded foam is bonded PU scrap — dense, firm and load-bearing with instant recovery. Memory foam is a viscoelastic virgin foam that softens with body heat and recovers slowly. They behave in opposite ways and are not interchangeable.
Is rebonded foam suitable for protective packaging?
As a structural base layer under heavy static loads, yes. It is too firm to cushion an impact on its own, so for drop protection it is normally combined with a softer EPE or PU top layer.
Need PU Foam Fitments for your product?
We manufacture pu foam fitments at our Rajkot unit and dispatch across India. Send the product, size or weight and monthly quantity and we specify and quote within one working day.
Or read the full specification: PU Foam Fitments