Reconstituted Foam Sheet

Reconstituted Foam Sheets for Heavy-Duty Use

Reconstituted foam is produced from polyurethane foam offcuts which are granulated and bonded under pressure to create a dense, durable material. The result is a significantly heavier and firmer product than conventional upholstery foam, making it particularly useful where support, durability and resistance to repeated loading or impact are required.

It is commonly used for:

• contract and commercial seating
• bar stools and fixed seating
• banquette seating
• gym equipment and exercise pads
• impact and protective matting
• firm upholstery support layers
• packaging and protective applications
• specialist manufacturing and fabrication

The correct grade will depend on how the foam is being used rather than simply choosing the highest number.

Choose Your Reconstituted Foam Grade

6lb Reconstituted Foam

6lb recon foam is the lightest of the three reconstituted grades available and is a good general-purpose choice where a dense, firm and durable foam is required.

Typical applications include:

• contract seating
• bar stools
• commercial upholstery
• seating support
• gym and exercise equipment
• protective padding
• general-purpose fabrication

It can also be used as a firm base or support layer beneath a softer upholstery foam, allowing the upper foam to provide comfort while the recon layer provides additional support underneath.

8lb Reconstituted Foam

8lb reconstituted foam provides a heavier-duty option for applications requiring greater density and resistance to repeated loading.

Typical uses include:

• heavy-duty commercial seating
• gym equipment
• exercise and protective pads
• impact applications
• contract upholstery
• manufacturing components
• firm support layers

The increased density makes 8lb recon particularly useful where the foam will be subjected to regular or demanding use.

10lb Reconstituted Foam

10lb recon foam is the highest-density reconstituted grade in this range and is intended for particularly demanding support and impact applications.

It is commonly selected for:

• heavy-duty gym equipment
• impact and landing mats
• protective padding
• specialist commercial applications
• high-load support layers
• industrial and manufacturing uses

10lb should not automatically be regarded as the best choice simply because it is the highest grade. For many seating and upholstery applications, 6lb or 8lb may be more appropriate.

What Is Reconstituted Foam Used For?

The dense structure of reconstituted foam makes it useful in applications where ordinary seating foam may be too soft or where additional support is needed.

Contract and Commercial Seating

Recon foam is widely used in commercial seating applications including bar stools, banquette seating, restaurant seating and other high-use furniture.

Depending on the application, it may be used as the main padding material or as a supporting layer beneath a softer comfort foam.

Gym Equipment and Impact Protection

Higher-density recon foam is commonly used for gym equipment, exercise pads, protective padding and impact matting.

The appropriate grade and thickness will depend on the level of impact, loading and cushioning required.

Upholstery Support Layers

Reconstituted foam can be particularly effective when used beneath a conventional upholstery foam.

A dense recon base provides support while a softer foam above it provides the required seating comfort. This type of layered construction is often useful where additional support is required without making the complete cushion excessively firm.

Reconstituted Foam, Recon Foam, Chip Foam or Rebond Foam?

You may see this material sold under several different names.

Reconstituted foam, recon foam, chip foam, rebond foam and rebonded foam are commonly used to describe foam made by processing polyurethane foam offcuts into smaller pieces and bonding them together to form a new dense material.

The terminology varies between manufacturers and suppliers, but customers searching for recon foam sheets or chip foam sheets are generally looking for the same type of product.

The distinctive multicoloured appearance of reconstituted foam comes from the different polyurethane foam offcuts used during manufacture.

A Practical Use for Foam Offcuts

Reconstituted foam makes productive use of polyurethane foam trim and offcuts generated during foam manufacture and conversion.

Rather than the material simply becoming waste, suitable foam is processed and bonded into a useful new product with its own range of demanding applications.

This makes recon foam quite different from conventional virgin polyurethane upholstery foam, both in its appearance and physical characteristics.

Reconstituted Foam Sheet Sizes and Thicknesses

Choose:

• 6lb, 8lb or 10lb grade
• required sheet size
• required thickness
• quantity required

If you are unsure which grade is most suitable, contact the Status Fabrics team before ordering and tell us how the foam will be used.

Need Foam Cut to Size?

If you do not need a complete sheet, Status Fabrics also offers Foam Cut to Size for customers requiring foam manufactured to specific dimensions or shapes.

Cut-to-size foam can be a better option where you need finished components rather than sheet material for further cutting in your own workshop.

If you are comparing different types of sheet foam, Shop All Foam Sheets to view the wider range of upholstery, memory, reconstituted and specialist foams available from Status Fabrics.

Buying Reconstituted Foam by the Block?

If you use reconstituted foam in volume, Status Fabrics can also quote for complete foam blocks, either supplied whole or slit into sheets to order.

We can provide two straightforward options.

Whole Block Price

Purchase the complete reconstituted foam block and have it delivered as a full block, ready for cutting or conversion using your own equipment.

Full Block Slit to Order

Purchase the complete block and have Status Fabrics slit the entire block into foam sheets to your required thickness before dispatch.

This can be a practical option for manufacturers, upholsterers, foam converters and other businesses regularly using larger quantities of recon foam or reconstituted foam sheets.

Whole-block prices are quoted at the latest available market price rather than being fixed online, helping ensure the quotation reflects current material costs and availability.

Email sales@statusfabrics.com with the grade, quantity and required sheet thickness for the current whole-block or full-block slitting price.

If you do not require a complete block, continue to order the quantity you need from this reconstituted foam sheet product.

For more information about full-block supply, pricing and conversion, read Get the Latest Foam Block Prices.

Need Help Choosing the Right Recon Foam?

Choosing between 6lb, 8lb and 10lb reconstituted foam depends on the application, required support and the amount of loading or impact the foam will experience.

If you're unsure which grade is appropriate, speak to the Status Fabrics team before ordering.

Telephone: sales@statusfabrics.com

You can also contact us with your dimensions, application and required quantity and we'll help you choose the most suitable option.

For orders over 30 sheets or full block pricing please contact us directly for volume pricing.