The specifications that define rebonded foam are density (DNS), form — block or cut — dimensions and packing. YAYLA confirms a short, exact set: DNS 50 and DNS 60, block or cut, standard and custom sizes, sheet or roll packing. Thickness, block dimensions and tolerance are set per order and should be requested in writing.
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What belongs on a rebonded foam datasheet?
A rebonded foam datasheet carries four headings: density, form, dimensions and packing. Density is written as DNS and means kilograms per cubic metre — DNS 50 is roughly 50 kg/m³, DNS 60 roughly 60 kg/m³. Those are the two grades YAYLA confirms for its rebond, and the choice between them follows the load the layer will carry.
Form says whether the material leaves as a whole block or already cut. Dimensions are the length, width and thickness of the delivered piece. Packing is either flat sheets or a roll. Together the three decide the state in which the material reaches your own line, which is why they need settling before price does.
The two headings most often confused are density and hardness. Density is mass per unit volume; hardness is the force needed to compress the material by a set amount. They are independent properties: two sheets sharing a DNS figure can differ in firmness, so a DNS number alone does not describe comfort.
Hardness, compression set and tolerance in millimetres are measured values, and no figure for them is published here. Where your specification calls for them, ask for them in writing with the order rather than assuming a number — the conditions a figure was measured under decide as much as the figure itself.
Block or cut: what changes in your own process?
A block is the material before slicing. A buyer taking blocks sets thickness at their own machine, changes dimensions between runs without placing a new order, and can nest several different parts out of one block. What that flexibility costs is a horizontal cutting line, the floor space it occupies and someone to run it.
Cut means the material arrives at its final dimension. The machine, the labour and the offcut all stay on the supplier's side; in exchange, every change of dimension becomes a new order rather than a machine setting. That is the sensible option where sizes are settled and the production plan repeats.
Offcut arithmetic is particular to rebond: the piece left over from cutting is the very raw material the product is made from. If you have a route back to a recycler, the offcut is not worthless. If you do not, buying blocks means taking on the storage and disposal of that offcut as well.
Finally, look at handling. A block is one heavy piece and needs a forklift and room to manoeuvre. Cut sheets stack and are usually moved by hand. Measuring your own loading area and storage height before deciding heads off a problem that is awkward to solve afterwards.
Sizing and packing follow from whether you cut
Standard sizes suit the buyer who is going to cut anyway: the sheet arrives at a stock dimension and extracting the yield is your job. Custom sizing is for the buyer who does not cut — the piece arrives at final dimension and no trimming station is needed. Both are available, and which works out cheaper depends on whether your offcut has anywhere to go.
In packing, the difference between sheet and roll is a transport one. Flat sheets keep the piece flat, which is what a gluing or lamination line wants, and they stack square on a pallet. Rolling wins volume in the vehicle, but only where the sheet is thin and flexible enough to wind without creasing; a thick, high-density piece does not roll.
Material that arrives rolled should be given recovery time once opened. A sheet measured or laminated before it has been laid flat and allowed back into shape gives a reading you will not get again. For the same reason, let the material reach ambient temperature before you cut it.
High-density material resists permanent deformation better than soft foam, but it is not immune to it. Three storage rules are enough:
- Keep it flat and clear of the floor.
- Keep it out of prolonged direct sunlight.
- Stack nothing heavy on top.
What should you send when you request a quotation?
Five pieces of information are enough to make replies comparable:
Cubic metres matter because foam is sold by volume. Two suppliers quoting per sheet from different sheet sizes cannot be compared at all; the same two quoting per cubic metre can. Converting your own requirement to m³ before you send it makes the replies far quicker to read.
The fifth item — which layer the material goes into — is the one buyers most often omit and the one that saves the most time. Saying the piece is a base layer under a pocket spring unit, or an underlay beneath carpet in a retail floor, lets the supplier tell you whether the grade you asked for is the right one. If you are unsure of the grade, describe the application instead of naming a number.
The last step is a sample. Ask for a sample of exactly the grade you intend to order and check it yourself: weighing a piece of known dimensions and comparing it with the declared DNS takes a few minutes. If the declaration and the scale disagree, every other heading on the sheet is in question too.
- Finished dimensions (length × width × thickness) with the tolerance you can accept.
- Quantity, in pieces and in cubic metres.
- Block or cut.
- The density grade: DNS 50 or DNS 60.
- The layer the material goes into, together with the load it carries.
| Specification | What it means | Why it matters | What YAYLA confirms |
|---|---|---|---|
| Density (DNS) | Kilograms of material per cubic metre | Sets load-bearing capacity and resistance to permanent deformation | DNS 50 / DNS 60 |
| Form | Whether it leaves as a whole block or already cut | Decides who runs the cutting and who keeps the offcut | Block or cut |
| Dimensions | Length, width and thickness of the delivered piece | Governs yield and whether the piece fits without further trimming | Standard and custom sizes — state yours in the request |
| Packing | How the material is presented for transport | Affects loaded volume and the waiting time before use | Sheet or roll |
| Hardness | Force needed to compress the material by a set amount | Determines feel and support independently of density | No figure published — describe the layer and ask for a sample |
| Compression set | Thickness permanently lost after a sustained load | Indicates how long the layer keeps its height | No figure published — request it in writing if your specification needs it |
| Dimensional tolerance | Permitted deviation from the nominal measurement | Decides whether sheets stack and laminate without correction | No figure published — agree it on the order |
Frequently Asked Questions
- Which DNS grades is rebonded foam produced in?
- YAYLA produces its rebonded foam in DNS 50 and DNS 60. DNS 50 means roughly 50 kg/m³ and DNS 60 roughly 60 kg/m³; the higher grade suits base layers that stay under load, the lower one intermediate and filling layers.
- What thicknesses is rebonded foam cut to?
- Thickness is set per order, and no standard thickness list is published here. State the thickness you need and the tolerance you can accept in your request, and ask for both to be confirmed in writing before production starts.
- Should I buy block or cut?
- Buy the block if you have your own cutting line: you then set thickness and dimension at your own machine and change them between runs without a new order. Without a cutting line, take it cut to size, because the machine, the labour and the offcut then stay on the supplier's side.
- What information should a quotation request contain?
- Send five things: the finished dimensions with the tolerance you accept, the quantity in both pieces and cubic metres, block or cut, the density grade, and the layer the material goes into. Those five are what make two suppliers' replies comparable with each other.
- Are hardness and compression-set figures available?
- Both are measured results and no figure for them is published here; if your specification requires them, request them in writing with the order. In most cases describing the layer and the load it carries produces a more reliable recommendation than naming a number.
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Used in These Sectors
See the glossary for terms: Rebonded Foam, DNS (Density Grade), Density, Hardness, Compression Set, Block Foam, Sheet / Slab, Cutting to Size
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