Laminated foam (composite foam) is produced by bonding a surface material — aluminium foil, non-woven fabric, leather, flannelette or PE film — to a closed-cell foam base such as XPE, IXPE or IXPP. The result combines the insulation, cushioning and light weight of foam with the reflectivity, strength, breathability or aesthetics of the facing layer.

Bofeng Foam runs in-house lamination and manufactures four types of laminated foam products. Use this page to compare them and find the right composite for your application.

Our 4 Laminated Foam Products

1. Aluminium Foil Laminated Foam

Foam faced with reflective aluminium foil. It reflects radiant heat, blocks moisture and provides excellent thermal insulation for roofing, ducting, cold-storage and automotive applications.

2. Non-Woven Laminated Foam

Foam bonded to non-woven fabric for a soft, breathable, abrasion-resistant surface. Used in car interiors, carpet backing, bedding and medical supplies.

3. Leather Laminated Foam

Natural or synthetic leather laminated onto soft foam. It combines the comfort and insulation of foam with the durability and premium look of leather for automotive seats, furniture and sporting goods.

4. Flannelette Laminated Foam

Foam faced with fleece (flannelette) for a soft, warm, comfortable touch. Widely used in bedding, cushions, garment linings and gift-box packaging.

Lamination Methods We Offer

  • Flame lamination — heat-fusing the foam skin to the facing layer, no adhesive needed.
  • Hot-melt / glue lamination — for materials that need a bonding layer.
  • Single- and double-sided lamination, plus back-adhesive options.

Applications of Laminated Foam

  • Construction: roof insulation, foil-faced underlayment, moisture barriers.
  • Automotive: interior sound insulation, seat padding, door panels, engine-compartment insulation.
  • Packaging: protective cushioning and heat-preserving packaging for fragile goods.
  • Furniture & bedding: sofa cushions, mattress toppers, carpet backing.
  • Medical: dressings, bedding and cushioning that must stay soft and hygienic.

Custom Foam Lamination Service

Tell us your surface material, base foam, thickness and dimensions and we will produce a laminated foam sheet to your specification. We support OEM / ODM orders from sample to mass production.

Request a laminated foam sample or quote →

Laminated foam FAQ FAQ

What is laminated foam used for?

Lamination lets one sheet do two jobs. Aluminium foil adds a radiant barrier and a vapour barrier to a thermal insulation layer, at the same time as the foam decouples and cushions. Non-woven fabric gives a bondable, low-friction surface for automotive and construction use. Leather and flannelette provide a finished appearance for consumer and interior products, and PE film closes the surface against moisture and dust. In each case the base foam is still chosen for the mechanical job it does.

Which facings can you laminate?

Aluminium foil, non-woven fabric, PE film, leather and flannelette are the facings we laminate, in single or double sided form, onto XPE, IXPE or IXPP base foam. Because the lamination happens in the same factory as the foaming, the facing, the adhesive and the foam grade are specified together rather than bought as three parts and bonded by a third party.

Does adding a facing reduce the insulation performance?

No — a metallic foil facing normally improves the thermal performance of the assembly, because it adds a radiant barrier to the conduction and convection control the foam already provides. The closed-cell foam still absorbs 0.2% or less water by the GB/T 1034 method 4 test, so the layer does not lose its insulation value in damp service, and the foil acts as a vapour barrier in the same thickness.

Can laminated foam be die-cut or CNC-routed after bonding?

Yes. Laminated stock is cut after bonding, so the facing and the foam are cut to the same profile in one operation. This matters for parts where the edge has to be clean and the facing has to stay bonded right to the perimeter, such as underlayment panels, automotive trim and packaging inserts.

How thick can a laminated composite be?

The base foam can be a single layer or a heat-bonded multi-layer block. XPE and IXPE bond up to 200 mm, IXPP up to 100 mm, and the facing is laminated to the finished thickness. If the part needs to be thick but light, a laminated build is usually thinner and lighter than the equivalent solid block.

Related Materials

See also: All foam materials · XPE foam · IXPE foam · IXPP foam