How do they make eggcrate packing foam? I had always
assumed it was molded into that shape, but I had the
opportunity today to look at two interlocking pieces of
such foam, and they obviously started life as a single
piece of foam and were then cut in half in an eggcrate
shape. But, try as I might, I can’t imagine a saw that
could could accomplish such a task. Can anyone enlighten
me?
Thanks in advance for any wisdom that is proffered.
Maybe they deform the foam, then just make a straight cut.
I don’t know the actual process used to manufacture said foam, but I wouldn’t abandon the molding hypothesis too quickly. Why couldn’t the mold be shaped so that the two pieces fit together snugly? In this day of computer-controlled machine tools it’s not hard to conceive of a milling machine capable of making such a mold.
According to the Polyurethane Foam Association, the foam is deformed and cut to produce the convoluted surface of egg crate foam. Read all about it here. Ain’t the internet grand? I’ll sleep easier on my egg crate mattress tonight, secure in my knowledge of it’s origin.
Wow! I never would have thought of that. Very cool. Thanks to everyone who replied.