Convoluted Foam Sheets, Rolls & Egg Shell Foam

TCH carries a variety of convoluted sheet foam. Their unique production methods create a strong, lightweight foam that is highly resistant to decay and has superior insulation properties. The range of thicknesses available combined with a durable finish that can be etched or painted makes them ideal for both indoor and outdoor applications.

TCH offers manufacturers the highest quality egg shell foam sheets and fabricated convoluted foam on the market. Their unique production methods create a strong, lightweight foam that is highly resistant to decay and has superior insulation properties. The range of thicknesses available combined with a durable finish that can be etched or painted makes them ideal for both indoor and outdoor applications. Additionally, the fast delivery times and cost savings provided by TCH on convoluted foam rolls make it an attractive option for many manufacturers in need of quality convoluted foam sheets at an affordable price.

Frequently Asked Questions on Convoluted Sheet Foam

What is convoluted sheet foam?

Convoluted sheet foam, also known as egg crate foam, is a flexible polyurethane foam featuring a wave-like pattern of peaks and valleys. This unique texture enhances cushioning, airflow, and shock absorption, making it ideal for packaging, soundproofing, and bedding applications.

Why is it called egg crate foam?

It’s named for its surface pattern, which resembles the shape of an egg carton. The alternating ridges and valleys help distribute weight evenly and improve ventilation in mattresses, cases, and protective inserts.

What are the common uses of convoluted foam sheets?

Convoluted foam sheets are used in a variety of applications, including:

Protective packaging for electronics, tools, and delicate items
Soundproofing and acoustic treatment to reduce echo and vibration
Mattress toppers and medical cushioning for pressure relief
Case and container inserts for safe transport and storage

What materials and densities are available?

TCH convoluted foams are typically made from polyurethane, available in polyether and polyester formulations.

Polyether foam offers flexibility and moisture resistance.
Polyester foam provides higher firmness and durability for heavy-duty use.
You can also choose from different densities depending on how soft or firm you need your cushioning.

How is convoluted foam made?

Convoluted foam is created by slicing and compressing a flat foam block using specialized blades or rollers. The foam is then expanded, forming the characteristic peaks and valleys that improve airflow and impact resistance.

How do I choose the right convoluted foam thickness and pattern?

Shallower patterns work best for sound absorption or light cushioning.
Deeper patterns provide better shock absorption for packaging or transport.
Common thicknesses range from 1″ to 3″, but TCH can provide custom sizes and profiles based on your application.

Can convoluted foam be used for shipping protection?

Yes — convoluted foam is excellent for light to moderate shipping protection. The peaks compress to absorb shocks and vibrations. For heavier equipment or harsh shipping conditions, pairing it with solid foam bases or custom-cut inserts is recommended.

Is convoluted foam good for acoustic insulation?

Yes. The irregular surface helps scatter and absorb sound waves, reducing echo and improving sound clarity. It’s commonly used in recording studios, machine enclosures, and server cabinets to control noise.

Can I order custom-cut convoluted foam sheets?

Absolutely. TCH offers custom-cut convoluted foam solutions in various densities, dimensions, and profiles to fit cases, racks, or specialized enclosures.

How should I maintain and store convoluted foam?

Store in a dry, cool area away from sunlight and humidity.
Avoid over-compression to maintain its rebound quality.
Clean gently using a vacuum or soft brush — no harsh chemicals.
Proper maintenance helps extend the foam’s lifespan and performance.

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Convoluted Sheet Foam