Foam forming processes

Does anyone have experience with forming open celled foam. My ideal foam would have good acoustic absorption and be non-degrading. I am going to skin it with fabric so UV is probably not an issue.

I am especially interested in the process used to make egg crate sytle foam sheet(sometimes used on matresses). Even the name of this process (skyving?). I think a similar tool could be used to make my part.

If anyone knows of a producer of egg crate foam or has any other ideas or foarming this stuff please reply.


“egg crate” foam sheets are cut from 1 sheet fed through a roll die, hence they fit perfectly back together. Many different thicknesses can be fed through, but the depth and periodicity of the peaks and valleys come from the blades on the roll die. Most custom foam fabricators have the equipment to make “egg crate” sheets.