Manufacturing Strategy

The testing of any performance product is necessary to ensure that it performs exactly the way it is advertised, and that it will offer performance that matches its claims. For some products, proving they work is incredibly easy. Something like a water bottle not leaking is assessed quickly and conclusively. Less-tactile items require more effort to quantify their performance. Sound treatment is one such product, as sound waves aren’t something we can see or hold. For this reason, we need to rely on technical performance values rooted in science as a basis for reference when comparing products.

Acoustical testing, performed by qualified, independent laboratories, is necessary to validate the performance of a foam deadening material. When assessed in a laboratory testing setting, a foam test generates comparable factors like noise reduction and sound transmission that can be applied across a field of products. This provides a structured way of identifying what products address what frequencies and how well. A test sound of varying frequency is played in rooms with and without the treatment materials, and levels of sound are recorded before and after to create the performance values consumers rely on.

It’s also important to perform testing periodically, as changes in the raw material that sound treatment is manufactured from may impact performance results. Fabrics used in covering panels also have an influence on a product’s performance. As sound is non-tactile, products may make claims stating that they can perform in ways they are incapable of, solely because the average person has no way to prove they will or won’t until after purchase and installation. Acoustical testing is the best way to identify performance values in sound deadening products, so you can make a decision that’s right for you and your space.

Whether you’re cheering on your team at the World Series or rooting for your kids in their youth soccer league, a little team spirit always makes the games more fun and interesting. And while we can yell until we lose our voices, showing our spirit is much easier than saying it and foam products are one of the best ways to let your allegiance be known.

The biggest icon of the fan accessory world is the foam finger. These have come a long way since papier mache, and it’s difficult to go to a game at any level without seeing the affirmation that your team is, in fact, number one. These are cut en masse from soft foam blocks and are often used as fundraisers or giveaways in contests because of their affordability. Today, there are multiple designs and patterns used, many tailored to individual teams. Swords, talons, bear claws, and thumbs-up are just a few of the personalized patterns fans enjoy cheering with.

Cheering all day at the game can get uncomfortable though, from the hard, molded plastic seats or cold metal bleachers. This is where foam steps in again, to make showing your fandom that much easier. In stadiums that permit them, cushioning bench pads soften hard seats, relieve pressure, and make it much easier to enjoy the whole game. The cushions pads and softens, but can also be used to show spirit. Cushions come in various colors so you can keep your team colors consistent, and logos go even further in showing pride for your team.

Before you head out to the stadium, make sure you’re well equipped to let your favorite team know that you’re on their side.

Often the first thing people consider when shopping for a mattress is the material it will be made of. This is certainly important, but shouldn’t be the first thing evaluated. The size of a mattress can play just as much of a role in your enjoyment as the materials it is made of. In nearly every case, the most basic rule of thumb is that people should get the largest bed they have the space for and can afford, but there are a handful of other factors that contribute to deciding what size bed you want, whether it’s a traditional bed, an air bed, or a memory foam mattress.

The first way to consolidate your size options is to consider if you’ll have one or two people sleeping in the bed. If you aren’t sharing a bed, you still have the full range of mattress sizes to consider. But if you do plan to share a mattress, this reduces your selection by shaving off some of the smaller sizes. It’s obvious that twin bed size dimensions won’t provide enough space for two people, but one of the mistakes new couples often make is thinking a double or full mattress offers sufficient space. Alone, a full mattress can feel spacious, offering plenty of room to spread out. But with standard widths of 54 inches, full mattresses only offer 27 inches of personal space to each person on it. Think about that; will you be able to stay comfortable sleeping in a space barely over two feet in width? Probably not. It’s suggested for most couples to use queen mattresses at the very least, to offer enough space for both people to comfortably sleep.

Families with children who like to crawl into bed with their parents first thing Saturday morning, or people with large pets who commandeer a significant amount of bed space often choose to have a king size mattress. This provides even more space for sleep, whether it’s for two people who require extra room, or to accommodate that extra addition a child or dog presents. And of course, some people who sleep alone may just want to have that much space.

More frequently, teens are using full size mattresses, instead of the traditional twin, to accommodate growing bodies. XL varieties of twin and full mattresses also exist to provide extra length for taller people, and “California” varieties of queen and king size mattresses give extra length on larger sizes as well. You can even attach headboard furniture to the bed, customizing it to your preferences. As you can see, a lot goes into picking a mattress before you even give it the test-run in the store.

Making an impression and catching the public’s eye is one of the most important aspects of marketing your business. In a world saturated with clichéd statements and gimmicks designed to draw your attention to products and services that are all flash and no substance, it takes more than fliers and web ads to get through to people.

One of the best ways to do this is with a bold and attractive business sign in front of your store. Signs establish credibility by helping to identify you as a part of the community; a part that’s invested and there to stay. Unfortunately, these can be fairly costly, when considering the materials, customization, and installation involved. To save your business’ bottom line, while still offering precision and attractiveness, turn to exterior foam signage.

Lightweight and easily customized by computer-controlled machinery, polystyrene foam signs are non-absorbent so they won’t rot from the elements, and are easily coated and painted to keep them looking pristine for years. Best of all, these foam signs can be designed to look like much more expensive materials, for a fraction of the cost. Die cut foam signs are often made with computer programs that offer unbelievable precision for bringing your business’ idea to life. Wording and logos can be created on CNC cut foam signs, and even 3-D designs or Styrofoam columns can be made by adhering multiple cut layers together. When finished and installed, foam business signs will tell your customers you’re a company of substance and give you the recognition and business you deserve.

Your bed is the cornerstone of your bedroom; after all, that’s where it got its name! Because of this, an unattractive or underwhelming bed can severely dampen the aesthetics of your room. Sheets and blankets go a long way in making your bed look attractive, but to really take your bed set to another level, a headboard makes a world of difference.

On a functional level, a headboard exists to guard the wall against damage and dirt from the person and the actual bed frame and mattress. To attach headboard materials for this reason is a smart investment, if only to protect the home. But more ornate and functional headboards exist that take it from a utility product to a functional addition to the bedroom.

For people looking to add a little pizazz to the room, decorative foam padded headboards can be upholstered to add aesthetics to a room. These pieces of cushion furniture also provide the benefit of soft padding to protect your head. Other headboards come with shelves for alarm clocks, books, glasses, and a place to charge your phone. Some can even accommodate lamps so you don’t need to get out of bed when you want to turn out the lights. Other kinds of headboards can be elaborate pieces of furniture, reaching to the ceiling and having sections and nooks built-in for a shelving unit. These are substantial installations and good ideas for people short on space, since a headboard serving as shelving means you don’t need additional storage space in a smaller room.

Some beds are built with a frame that is part of the headboard itself. These beds are essentially singular pieces of furniture and are often complimented by other aspects of bedroom furniture like end tables and dressers.

Artificial grass is quickly becoming more popular these days because of the benefits it provides in our homes. Artificial grass residential dramatically improves the aesthetic appeal of our house, it gives off a look that your lawn is always properly maintained. Nowadays, you can purchase cheap artificial grass in the market or through online suppliers. You just have to make sure that the online shop is legitimate if you wish to process an order through a supplier’s website.

Artificial grass will keep your lawn green no matter what season it currently is. Artificial grass requires less to no maintenance at all, you do not need to mow it nor water it even if it is blazing hot outside. Because it is maintenance free, you are almost immediately reducing your monthly expenditures on both water and electricity. You will never need to worry about cleaning the lawn during the weekend, you will now get more time to spend with your family and friends. Artificial grass is safe for your kids and pets, it does not require any chemical sprays that triggers skin irritation and allergies. Mud puddles will be a thing of the past when you have an artificial turf installed at home.

We have all dreamt of someday having a fairytale mansion, adorned with beautiful decorations and impressive halls, staircases, and balconies. As we grow older, many of us realize this isn’t as likely to happen as we once thought it was, but that doesn’t mean we can’t make the most out of what we do have.

Even the most modest homes benefit from architectural additions which can impact the feel, appearance, and even the value of the home. Of course, many additions can weigh heavily on a checkbook when there are many other things that need tending to.

There is a middle ground though, where design and appearance meets practicality and affordability, and that manifests itself in foam architectural pieces.

Cut on computer controlled machines, polystyrene craft foam can be manipulated into near-replicas of interior design components that cost and weigh 10 times more. With a sealant and paint, comparing Styrofoam columns or mountings to the “real thing” would result in two identical items.

One of the best uses for foam is in crown molding, as soft polyurethane foam can be trimmed easily at home and manipulated into fitting into tight spots without the difficulty of traditional molding materials. Molding is made in any size or pattern and even in custom designs. Applying sealant and paint, you can have DIY molding that adds understated elegance and an open feeling to any room.

Styrofoam columns are perfect for creating an antique feel in home libraries or theaters. Again, the foam, this time polystyrene, can be cut and painted to match any surroundings. With simple adhesive, the columns can be mounted to walls without worry of weight or support that come with stone or wooden additions. The backs of half-columns can also be carved out to hide blemishes or irregularities in a home. Lastly, outdoor molding and non-weight-bearing balustrades around windows or balconies can give your home the look you’ve always wanted at a price you didn’t think you could afford.

If you’re looking to add value to your home, or just take a step toward that dream home you’ve always wanted, foam architectural pieces are the perfect plan.

One of the first rites of passage for practically every student moving away for college is the dorm room. They are often smaller than the bedroom the student had growing up, and that is in addition to having to share the dorm with a roommate. This cutback on space and privacy can be tough to adjust to, but it’s something you can make the best of with a little ingenuity. Optimizing the space you’re given can be an experiment in creativity and something you look back on fondly as you reminisce post-graduation about your alma mater. Here are a few suggestions for ways you can personalize your dorm room while getting the most out of it:

• The Futon. The old college standby, this piece of folding platform furniture can be both the bed and couch a room needs. Replacing the stock futon pad with futon mattress foam can transform it from a stopgap purchase into a long-term solution by making it as comfortable as any individual bunk or sofa. Even if you have your own bed, having a couch that opens into a folding bed with mattress space is great for friends crashing for the night.

• Lofts. Creating a loft utilizes the vertical space in a room that would otherwise go unused, giving you more floor space. A loft can have two beds stacked on top of each other like bunks, or a single bed can be lofted up high with an open space for a computer desk or entertainment area beneath. This concept can be extrapolated into something as extreme as treetop sleeping quarters that are like adding an entire extra level to the room.

• Bean Bag Chairs. What’s more fun to sit on than a comfy bean bag chair? Perfect for studying, relaxing and anything between, bean bag chairs today come in many fabrics, colors, and sizes so you can find one that fits your personality and your space. Their free-form shapes fit into tight areas where conventional furniture won’t, and if you really need the extra space, just toss them on a bed or in the closet – good luck doing that with a recliner!

Have you ever wondered how some of your most comfortable pieces of furniture were made? Some things like a foam mattress or cushioning foam pad with clean, sharp angles would seem fairly simple to make with a straightforward cutting machine. But what about that ergonomically shaped office seat you sit in, or the custom foam packaging you ordered for your company’s promotional products? These have smooth, clean curves that would be impossible to cut with a straight blade. So what’s the secret? In many cases, these special forms are made with compression cutting technology.

The process of creating a smooth, custom piece of contoured foam is done with molds that capitalize on foam’s compressibility. Templates are made that reflect what the ultimate product is intended to look like. The material is passed through the machine under compression over these templates, and a blade passes through the foam directly above the template. This creates two interlocking forms; the interior piece that was “inside” of the template during compression, and the piece trimmed off the top above the blade. High points in the template create areas of greater compression, meaning more foam is squeezed into a smaller area. When released after cutting, this creates high points or peaks in the outer section that was cut above the blade, and lower valleys in the section that was under the blade, within the template under compression.

These templates can be made in virtually any pattern or design, with contours, curves and smooth tapers. The only thing that separates these forms from complete molding is the single flat side where the blade cut. The inside pieces are often used in cushioning foam for seat cushions and the like, while the outer sections of foam are used to create zoned mattresses for foam bedding.

When including decorative cushions and throw pillows as part of your home’s décor, even the smallest touch can make the difference between a run of the mill decoration and something that is elegant and kept for decades. These little touches are things we often don’t notice when they’re present, but if they aren’t there, we get the feeling that something is missing. These additions, like welting and buttoning, can add class and customization to throw pillows, a pattern cushion, or any other comfort decor in the home.

Welting on cushions and pillows, also called piping, is a thin cord of cotton or a similar solid material that is wrapped in fabric to match or accent a cushion’s cover and sewn along an outer seam. This technique is a clean way to cover seams in sofa pillows and an easy way to create a different kind of look. Welting can be done along the top and bottom seams of box cushions, patio furniture cushions, or the outer edges of pinched seam pillows. The box cushion welting reinforces the profile of thicker cushions and helps to keep the cover from sliding by adding a little more rigidity to the seam.

While welting can be used to make a crisp, contemporary look, buttoning can create a tufted appearance for a cushion that looks terrific with antique furniture or a room’s classic styling. Buttoning is done by running a thread through the form of the cushion and tying it off on both ends with a button. This creates a gentle bunching around the button, resulting in tufting. This style can be done with a single button in the center, four buttons located near the four corners of a cushion, or with five buttons, four in the corners and one in the middle. When the foam cushion insert is wrapped in fiberfill, tufting is even fluffier.

If you want to make a big difference with a small touch, welting and buttoning will fit the bill for your next cushion and pillow project.