Rebonded foam is a high-density material produced by coating foam pieces reclaimed from cutting and upholstery work with a binder, then pressing them under high pressure and steam. The mix is formed into a block in a cylindrical mould and, once cured and cooled, sliced to the required thickness. In the Turkish market it also sells as bondex and granür.
Last updated:
How it is made
Production starts with sorting the reclaimed foam. The pieces are reduced to a set particle size in a shredder, and that size governs the texture visible across the finished block's cut face.
The pieces are then coated with binder and the mix is loaded into a mould, where pressure and steam are applied. The steam cures the binder while the pressure compacts the mix to its target density — those two variables together set the DNS figure.
Once out of the mould the block is left to rest. Slicing before cooling and curing are complete leaves sheets whose dimensions shift afterwards, which is why resting is not a step that can be skipped.
Why is the density so high?
In foam blown directly, density is set by the chemical formulation. In rebonded foam it is mechanical: it comes from how much material is compressed into a given volume. That is why rebond reaches densities well above typical upholstery foams.
What high density buys in practice is load-bearing capacity and resistance to permanent deformation. Those are precisely the properties wanted in layers that stay under load for long periods — a mattress base layer, a gym floor, an underlay beneath carpet.
Density should not be confused with hardness. They are independent properties, and two materials sharing a DNS figure can differ in firmness.
Where is it used?
The most common use is mattress production: a rebond sheet sits above or below the spring unit as a support layer, delaying the collapse of the softer comfort layers over it.
In furniture it fills seat and back frames; in sports facilities it forms the floor layer under free-weight areas and mats; and beneath carpet or laminate it works as an impact-damping underlay.
In packaging it is chosen as moulded cushioning for shipping heavy or sharp-cornered items, because its density lets it hold shape through repeated impact.
What should you check before buying?
Look at the cut face first. An even, void-free section means the mix was properly coated and adequately pressed; visible voids, or coarse pieces clustered in one spot, say the block is not the same density throughout.
Second is dimensional tolerance. Sheet thickness should hold end to end — a block sliced before it rested long enough shows its thickness deviation only later.
Third is how the DNS figure is verified. Density can be checked by weighing a piece of known dimensions, and if the declared figure and the scale disagree, every other specification is in question too.
| Stage | What happens | Property it sets |
|---|---|---|
| Sorting | Reclaimed foam is separated by type and colour | Texture across the cut face |
| Shredding | Pieces are reduced to a set particle size | Evenness of the section |
| Binder application | Pieces are coated with binder | Uniform strength through the block |
| Pressing | The mix is compacted in the mould under pressure and steam | Density (DNS) |
| Resting | The block cools and finishes curing | Dimensional stability |
| Slicing | The block is cut to the required thickness | Sheet thickness tolerance |
Frequently Asked Questions
- What is the difference between rebonded foam and ordinary foam?
- The difference is method and density: ordinary foam is blown chemically as a single piece, while rebonded foam is made by pressing existing foam pieces together. Rebond is therefore denser and more load-bearing, and ordinary foam is softer and lighter.
- Is rebonded foam a recycled material?
- Yes. Its raw material is the foam offcuts that cutting and upholstery work leave behind, which are turned back into material instead of becoming waste. The coloured particles visible in a cut section are the visible evidence of that.
- Which DNS grade should be chosen?
- The choice follows the load the layer will carry and how long it stays under it. Base layers that are permanently loaded take a higher DNS; intermediate and filling layers take a lower one. To settle on the right grade for your application, see the options on the product page or ask us.
- Should it be bought as block or as sheet?
- If you have your own cutting line, buying the block is more flexible: you set the dimensions to suit your own production plan. Without a cutting line, taking it as sheet cut to size is more efficient in both offcut and labour terms.
Related products
Used in These Sectors
See the glossary for terms: Rebonded Foam, Bondex, Granür (Granulated Foam), DNS (Density Grade), Pressing, Binder, Reclamation
Related guides
Let's Determine the Right Material for Your Project
Our technical team is ready to help you identify the most suitable product and solution for your needs.