The applications for flexible foams are limited only by one’s imagination.
Flexible Foams Overview
With 5 production facilities across the United States, American Excelsior provides “same source” locations close to major volume customer accounts, as well as offering smaller customers personalized service. Our foam fabricators have a wealth of industry knowledge and experience which they share with our customers every day – from reviewing blueprints to designing parts and developing prototypes.
AEC’s custom foam operations are used by a number of industries for a wide range of products, including, but not limited to: polyether foams for automotive door panels; polyester foams for government packaging; cross-link polyethylenes for protection in athletic equipment; high resilient foams for airport seating; and anti-static foams for packaging of sensitive computer equipment. The most common applications include athletic, automotive, furniture, electronics, marine, medical, novelty and packaging.
The longevity of our employees is also a valuable asset in the fabrication process. An employee who has worked in the same location for many years is intimately familiar with the parts we fabricate for our loyal customers. Whether it is open or closed-cell polyurethane or polyethylene, American Excelsior is well suited to address the needs of today’s cushioning and protection requirements.
In addition, if your company or customer is concerned about the environmental impact of flexible foams, our new Earth-Cell™ foam option may be the right choice for you.
One of our newest offerings is a line of high-quality impact mats which were developed for use as medical floor mats, but which can be used in a variety of ways to reduce impact or fatigue. These mats are made using a unique dual-density process and have distinctive design, comfort and impact characteristics. We can also accommodate special orders to add your company name and/or logo to the mat. Contact us for more information.
American Excelsior provides flexible foam solutions for package & case inserts using a wide variety of flexible foams. In addition, our foams can be “flocked” or flame-laminated to give your insert a professional finished appearance of your product. Whether you are packaging a sensitive electronic instrument or producing a display package for retail, American Excelsior has a wide variety of flexible foams to meet your requirements. For more information please contact a representative in your area.
Dunnage & Protective Packaging
American Excelsior provides flexible foam solutions for dunnage and protective packaging and applications can be found in automotive returnable or non-returnable totes to surface protection of finished parts. For more information please contact a representative in your area.
Seating & Bedding
American Excelsior has been producing and designing flexible foam products for the marine industry since our early introduction of flexible foams back in the 1950’s and today, we are proud to say that we have business relations within the marine industry that go back 40 plus years and for one reason-they trust American Excelsior with their flexible foam requirements and they know that we will keep them abreast of new technologies and new products that will allow them to be the leaders in their market.
Insulation, Acoustical & Protection
In addition to marine seating and bedding foams, American Excelsior also provides flexible foam solutions for marine insulation, sound control and even foam protection pads to protect your vessel during transit. Foams can be laminated with secondary backings such as PSA adhesive to help hold in place or a reflective aluminized mylar film for heat reduction while providing additional light in engine compartments.
As a customer of American Excelsior, you should always turn to us when you think of a flexible plastic product and foams for flotation are just another example of the many product offerings we have. In addition to flotation foams, American Excelsior can also design and manufacture closed-cell foams that are flame-laminated with a wide variety of fabrics which can be embossed or molded to give you a finished product such as a swim pad without the need of sewing.
AEC is a recognized leader in flexible vinyl and elastomeric coatings for foam patient positioning, wheel chair seating, physical therapy products. With ongoing patient safety concerns regarding blood borne pathogens and other contaminants, it’s essential that these foam coatings provide a sealed, fluid proof, combustion modified, cleanable surface while offering patient comfort and pressure relief. Products used in radiology applications [x-ray, CT, MRI] also require a radiolucent or “noise free” coating that will not interfere with imaging. Our specialty coatings offer tremendous durability, flexibility and color choice. They can be applied to both our molded and fabricated foams. They provide a sealed, cleanable surface that is fluid and chemical resistant. The protective coatings can also be easily screen printed. We offer water base urethane and vinyl, non-flammable flexible coating to market and also offer low VOC coating technology.
American Excelsior provides flexible foam solutions for medical seating, bedding or any application where patient comfort is desired. Our flexible foams can also be coated, flame-laminated with fabric, molded or made with secondary parts to help reduce your manufacturing process and provide a superior finished product.
American Excelsior provides flexible foam solutions for medical bedding.
American Excelsior provides flexible foam solutions for medical packaging.
American Excelsior provides flexible foam solutions for bedding mattresses.
Flexible foams are used in many promotional type applications where bright colors and flexibility are required. Some of those applications include:
Foam Hats used to support your local charity or sporting event
Foam #1 Fingers as seen at sporting events
Foam cubes for jump pits
Foam toys such as building blocks, puzzles and other flexible type toys
The list goes on and on, so if your project requires a flexible foam product, American Excelsior probably has the foam to fit your need.
Sofa / Chair Cushions
American Excelsior provides a wide variety of flexible foam products for use in furniture cushions, chairs, arm rests, back cushions or anywhere when comfort or a plush look is needed. Our product offering covers a vast range of products to assure that the performance and value of your finished product is being met. We have been fabricating flexible foams for the furniture and seating industry for over 50 years and our customers value us a partner in the success of their product and our people are willing to work your upholstery teams to better understand the performance of your finished product so they can assist you in the right choice of foams.
In addition to providing flexible foams for cushioning in chairs and sofa’s, American Excelsior provides flexible foams for the protection of your finished furniture. This includes Amcel polyethylene foam sheets or rolls available from 1/32″ to 1/2″, all the way to PE plank fabrication for heavy bracing of your finished product for shipment. If it’s comfort or protection, we can design the right product for the right application.
Packaging & Protection
American Excelsior provides flexible foam solutions for automotive sound dampening, vibration control or in areas where reductions of noise is needed due to moving parts or outside interference. Most foams can be laminated with secondary products such as PSA adhesive, Mylar films or other products to meet the demands of the application.
Acoustical & Vibration
Recreational / Athletic
Flexible foams have become the product of choice when it comes to protection cushioning in the athletic/recreational industry, but you need to be selective of that choice since there are so many products on the market all claiming to meet performance standards of some degree. For that reason, you should know and understand what those claims are so you can make the right foam choice for your finished product. With a wide variety of polyurethane, Polyethylene and cross-links foams, we can “design product neutral”, meaning we fit the right foam to the right application. Not try and and fit a particular foam to all applications just because we are limited in our product offering.
In addition to custom fabrication, American Excelsior can also mold, flame-laminate and provide a special process where fabrics are laminated to foam and then compression molded to give you a finished part. In many cases, this unique process can reduce or eliminate sewing or other secondary operations to your finished product.
Foam with Flocking
Flocked foams provides the feel and appearance of velvet on your foam and is great for display applications and it great for those times when you want to impress your customer and highlight the item being packaged or displayed. Great for promotional items, glassware, trophies, coins, pen and pencil sets and many more applications. For a sample of this material, contact your local American Excelsior office or call: (800) 326-FOAM.
Excelsior Wood Fibers
American Excelsior supplies excelsior wood fiber products to diverse markets for a wide variety of applications. From baled excelsior to aspen animal bedding to evaporative cooler pads, wood excelsior products have an almost endless list of applications. We offer more than 50 different cuts of excelsior fibers to meet even the most specialized applications.
We use Great Lakes, all-natural Aspen, as a wood source for all of our wood excelsior products. We purchase Aspen only from forest products companies that are members of the Sustainable Forestry Initiative program. This ensures that our vendors are following the best environmental and forestry management practices. We are proud of our environmental stewardship commitment.
Natural excelsior boxed excelsior and baled excelsior are offered for use in specialized packaging for retail outlets. Excelsior is easy to work with, safe, and 100% biodegradable. It is a favorite when used in wreaths, garlands, and fruit and gift boxes or baskets. Excelsior fibers may be shaped, sized, glued, molded, matted, or woven to fit numerous decorative applications.
In the packaging industry, wood excelsior is an ideal product to protect and cushion larger, heavier, or more irregularly shaped products (e.g. heavy parts or statuary products). The unique, curled excelsior fibers have a barbing feature that enables the fibers to interlock and provide excellent packing and packaged cushioning capabilities not found with other types of packaging materials. Furthermore, excelsior is biodegradable making it an environmentally safe product. For protecting smaller and lighter fragile products, such as china, glassware, and pottery products, our Curlex® packaging pads feature excelsior fibers encapsulated in the paper for natural cushioning.
Wood excelsior fibers are also widely used as a filtration medium, ranging from filtering oil in combustion engines to oil field filtering and vinegar filtration. The interlocking, barbing features of the fibers, combined with low moisture content from air curing, results in highly absorbent fibers capable of filtering without any artificial additives. In the construction industry, excelsior is frequently used in tunneling and pipe installations to fill void areas.
Other applications for wood excelsior fiber products include, among other things, use in ceiling boards, taxidermy, burn blocks at fire training schools, concrete extenders, oil booms, pipeline padding, and snake bedding.
We invite you to browse our wood fiber site to learn more about our products and contact us at email@example.com with any questions or call 866-934-2377 (Toll-Free). Our Customer Care personnel will work with you to select the excelsior product best suited for your needs.
For more information please contact a representative in your area.
Amexcoat™ Coated Foam Products
Amexcoat™ Coated Foam Products
Amexcoat™ is a new coating system that can be applied to most flexible foam products where comfort, protection or cushioning is required. Amexcoat™ products add strength and integrity to the foam while providing a high-end washable finish that is reusable and provides longer product life compared to most fabrics.
In addition to being durable, Amexcoat™ coated finishes are available in standard colors of blue and gray but can be formulated to custom colors with minimum production requirements. Our unique process can also eliminate the need for fabric covers which can become soiled and/or absorb contaminants, which may collect in the fabric stitching. We can even customize the appearance to a satin look or to a brilliant high gloss finish to give your product an impressive appearing sheen.
Amexcoat™ coatings can be found in such applications as: Medical for positioning or medical pads; Recreational for specialty indoor/outdoor uses; Marine for flotation pads; Athletic for such items as gymnastic equipment and multiple other uses and markets. In addition, an antimicrobial additive is available which helps reduce the growth of mildew and bacteria. If you want your product to have a durable, washable, attractive outer covering without fabrics, Amexcoat™ is your answer!
Fluid Resistant Properties – Keeps inside materials dry and free of contaminants. Flammability Characteristics – Passes UL94 HBF, can utilize California 117 and MVSS302 foams in conjunction with the coating and other combustion modified foams.
Durable Surface – High Tensile, Tear and Elongation properties.
Mildew Resistance – Contains an antimicrobial additive. Important in fighting mildew and bacteria.
Radiolucent – Can be used in XRay applications without distorting the image.
Color Stabilization – Doesn’t fade.
Reusable – Product can be easily cleaned for further use.
Eliminates the need for stitching joints as seen with fabric covered products.
Advantages over Competitive Products
Reusable – Competitive fabric wrapped products must be discarded if fluids seep into the product. Vinyl coated products can be cleaned and reused.
Versatility of Product – Can be used in outdoor applications without the need to store or dry out (i.e. Outdoor furniture).
Radiolucent – Transparent to radiation causing no distortion of image in XRay applications.
Cleaning – Can be easily cleaned with various cleaning products.
- Fluid Resistant Properties – Keeps inside materials dry and free of contaminants.
- Flammability Characteristics – Passes UL94 HBF, can utilize California 117 and MVSS302 foams in conjunction with the coating and other combustion modified foams.
- Durable Surface – High Tensile, Tear and Elongation properties.
- Mildew Resistance – Contains an antimicrobial additive. Important in fighting mildew and bacteria.
- Radiolucent – Can be used in XRay applications without distorting the image.
- Color Stabilization – Doesn’t fade.
- Reusable – Product can be easily cleaned for further use.
- Eliminates the need for stitching joints as seen with fabric covered products.
Advantages Over Competitive Products
- Reusable – Competitive fabric wrapped products must be discarded if fluids seep into the product. Vinyl coated products can be cleaned and reused.
- Versatility of Product – Can be used in outdoor applications without the need to store or dry out (i.e. Outdoor furniture).
- Radiolucent – Transparent to radiation causing no distortion of image in XRay applications.
- Cleaning – Can be easily cleaned with various cleaning products.
- Crosslink Foam
CurlFoam™ is an extruded Polyethylene cushioning product. Its unique cell structure, along with excellent physical properties, makes it the ultimate choice for various cushioning applications.
- CurlFoam’s open cell design makes it breathable and ideal for air circulation
- Available in a clear/white color
- A 100% recyclable product
- Does not absorb water and dries quickly
- Mold and mildew resistant
- Products are custom-made to meet your requirements, including custom weight firmness and exact dimensions manufactured to your specifications.
CurlFoam can be used in a wide-variety of applications, including:
- Medical Padding
Contact your American Excelsior Company Sales Representative for more information and to discuss if CurlFoam is the perfect fit for your project.
Dual Density Mat
Dual Density Mat
Dual Density Impact Reduction Floor Mat
MADE IN THE U.S.A.
Introducing our new Dual Density Impact Reduction Floor Mat—a multiple purpose impact reduction floor mat developed to aid in the reduction of impact injuries sustained while providing excellent comfort, safety and increased productivity in the workplace.
A durable, integrated slip-resistant top wear layer of high density vinyl foam polymerically bound to a soft, moisture resistant proprietary closed cell foam, with sweep edges allowing for easy wheelchair access. Our Dual Density impact floor mat was designed as one of the lowest profile mats available reducing the risk of being a trip hazard when being used in patient care and other various applications, offering easy on and off wheelchair and cart access. The Dual Density mat is resistant to degradation by inorganic acids, organic acids, reducing agents, detergent solutions, alcohols, aliphatic hydrocarbons, mineral oils, amines and aldehydes.
Independent lab testing conducted for Impact Attenuation per ASTM F-1292-04 indicated excellent impact absorption at 18” and below reducing the risk of injury when using our Dual Density floor mat on Vinyl Composition tile flooring and for patient care applications. Independent lab testing conducted met UL 94 HBF fire retardancy.
Dual Density Floor Mats can be embossed with company logos or taglines to promote your brand or product. Graphics are permanently embossed into mat surface. The impression finish can have a glossy, textured or frosted appearance. Standard stock mats are plain and do not contain any imprint.
Our standard mat is 29” x 70” x 5/8” and is not only durable, it has an integrated slip-resistant wear layer top made of high density vinyl foam that is polymerically bound to a soft moisture resistant proprietary closed cell foam. Mats are rolled and individually boxed for easy shipping and handling. Contact your local American Excelsior representative for more information.
In today’s economy, it is important for all of us to protect our environment and lessen our dependency on oil and other products that are volatile in the marketplace.
Here at American Excelsior Company, we have been manufacturing environmentally-friendly products even before other companies began focusing on the same issues. We never lost sight of the importance of ”green” products. We were the first company to introduce starch-based foams in the late 1980’s, and today we are introducing Earth-Cell, which is a bio-based foam that is an alternative to petroleum-based polyurethane foams.
We have worked closely with our raw material suppliers, as we know it is important to our customers to have a ”green” flexible foam. Using earth-friendly foams gives our customers the performance they expect on their finished product, but without adding cost. With our Earth-Cell product, we can provide earth-friendly products whose performance characteristics are superior to other foams due to improved ”cell” integrity.
Earth-Cell foams contain renewable based bio-polyol. This helps reduce our dependency on fossil fuels, reduces energy demand and creates a smaller environmental footprint. In addition, these hybrid foams are manufactured without harmful CFCs, and do not use alternative blowing agents.
Our Earth-Cell option is available for many of our flexible urethane foams. This allows us to incorporate bio-renewable polyols, such as soy, in the manufacturing of our product. While the amount of bio-based additives can vary by foam formulation, each and every drop of petroleum can make a difference to lessen our country’s petroleum consumption. You can be a part of this by requesting Earth-Cell for your flexible foam needs.
Whether your application includes cushioning, seating, protection or comfort, American Excelsior can now offer you and your customers the Earth-Cell option with a ”green footprint.”
If you would like to learn more about Earth-Cell, contact your local American Excelsior Sales Representative, or call 1-800-326-FOAM.
American Excelsior offers both molded urethane foam and crosslink compression molded foams, and each has their own unique properties to help satisfy customer needs. This is just another example of American Excelsior’s commitment to be able to ”design product neutral”. Meaning, we fit the best product to your application.
While most polyurethane foams are fabricated from sheet, bun or slab stock, there are unique shapes and applications that require molding and American Excelsior has an extensive molding line backed by many years of success. In addition to foam molding, component parts can be added to help reduce assembly at your plant or most foams can be coated to give you a finished part.
Polyethylene foams are more of a closed-cell nature and generally not used for applications such as furniture cushioning or bed mattresses. However, polyethylene foams are an excellent choice for such applications as tumbling mats, crash pads, surface protection, packaging and other applications where you may have high impact or extreme repetitive flexing.
There are also a wide variety of lower density (weight per cubit foot) polyethylene foams on the market which are used for light-weight packaging applications such as a separator pad for china.
Polyethylene foams are available in varying densities and colors and most are water and chemical resistant depending on the product choice.
American Excelsior can fabricate, mold, compression cut and laminate component parts to most of polyethylene foams.
Polyurethane foams are generally used for comfort, cushioning and protection. Generally, fabricated foams are those that you will find in furniture, bedding, egg-crate foam for packaging etc.
Polyurethane foams are available in a wide range of densities (weight per cubic foot) and IFD’s (Indentation Load Deflection) which is basically how soft or how firm a foam is. Most polyurethane foams are also available in colors and can be formulated to meet special specifications such as UL, California Tech Bulletin #117-2013.
In addition to the foams mentioned above, American Excelsior also carries a wide variety of speciality foams that are used for aviation, military, display, cosmetic, medical and a many other applications. These foams include, but are not limited to: Silicone foams, neoprene foams, foam with flocking, high resilient foams, polyester foams and latex foams.
If your application requires a plastic type material that is flexible, chances are American Excelsior has the product you are looking for.
Viscool® Visco-Elastic Foams
Viscool® Visco-Elastic Foams
American Excelsior Company takes pride in its history of being an Industry leader and innovator of Flexible Foams products, and we are proud to introduce our new line of open-cell, breathable ,Viscool® Elastic Foams.
Viscool Foams were designed and formulated exclusively to meet stringent specifications for improving air flow and enhancing performance and conformability. Its unique cell structure was specifically designed to reduce heat retention which is found in most high density viscoelastic (also known as slow recovery) foams.
Viscool allows for increased air flow which provides breath-ability to reduce heat, moisture retention, and provide optimal cool comfort to the user. Viscool is a perfect choice for applications in seating, support, bracing and offers a soft, comfortable, orthopedic pressure support while providing high energy absorbing impact characteristics. Viscool Foams’ air flow testing indicates an improvement of 35-90 times more air flow than other leading manufacturers of high density viscoelastic foams.
Are there any foams on the market that are considered environmentally-friendly?
Yes! There are flexible foams on the market that are made using non-oil based chemicals such as soy, and American Excelsior has a wide variety of optional “green” foams marketed as Earth-Cell™.
What is a board foot?
A board foot (b/f) is the industry standard for pricing flexible foam and is basically the same method used in the lumber industry to calulate wood. One board foot is: 12″ x 12″ x 1″. To calulate the number of board feet, simply take the length x width x thickness and divide by 144. Example: A 24″ x 24″ x 4″ piece of foam has 16 board feet.
What does IFD stand for?
Indentation Force Deflection which is a measure of the load bearing capacity of flexible polyurethane foam. IFD is generally measured as the force (in pounds) needed to compress a 50 square inch circular indent or foot into a 4″ thick sample, typically 15″ squarer, to a stated percentage of the sample’s initial height. Lower number ratings such as 15#-20# is soft and generally used for back or pillow type applications. The higher the number, the firmer the foam will be. Also used to be called “ILD (Indentation Load Deflection)”.
What does the “density” of foam mean?
Density is the measurement of the mass per unit volume and it is measured in pounds per cubic foot. Density is sometimes confused with the firmness of a foam. If you took a 12″ x 12″ x 12″ block (1 cu/ft) of a foam that is supposed to be a 1.8# density, it should weigh 1.8# with a normal tolerance of plus/minus .5#.
What does “reticulated foam” mean?
A Reticulated Foam is characterized by a three-dimensional skeletal structure with few or no membranes between strands. Reticulated foams are generally used as filters, acoustical panels, and for controlled liquid delivery. Reticulated foams are sometimes referred to as “filter foams”.
What does TDI stand for?
Abbreviation for toluene diioscyanate, a chemical used in the production of polyurethane foams.
Is there an easy way to cut foam at home?
Yes- Using normal safety precautions when cutting, an electric kitchen knife works quite well on most foams.
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American Excelsior understands your need for flexible foam documentation & specifications. This documentation is being gathered for this new web page. Until then, for more information please contact a representative in your area.
We believe in personal and professional attention to our customers and that is why during business hours, we have intelligent, enthusiastic, living human beings answering the phone. If you tell them what you want, they will either provide you with the information you need or will direct you to someone who can.
Flexible Foam Sales Representatives
John Bosch: Division Director — 412.721.1270
Kevin Coakley: 262.751.1421 — ND, SD, NE, MN, WI, IA,
Bill Edwards: 817.319.0620 — AZ, CO, NM, KS, OK, TX, AR, LA, MS, AL, GA, FL
Bill Kehoe: 216.744.5765 — MI, OH, KY, TN, ME, VE, NH, MA, RI, CT, NY, PN, NJ, DE, MD, WV, VA, NC, SC
Jeff Schlect: 509.969.4472 — WA, ID, MT, WY, CA
John Bosch: 412.721.1270 — WA, OR, NV, UT
Jamie Wellemeyer: 630.284.5202 — IA, MO, IL, IN, KY, TN
Gordy Zastrow: 920.242.3254 — MN, WI