TL;DR: Polyurethane foam is cut in industry using seven methods. Vertical cutting with a band knife and horizontal cutting are dominant - used by most furniture and mattress factories. CNC contour cutters or string cutting are used for complex 3D shapes.
Method 1: Vertical cutting with a band knife
Vertical cutting is the most common method in furniture and mattress production plants. The DZIERGWA vertical cutter type PPA cuts a foam block into slices of a given thickness - from 7 mm to over 1000 mm. The CNC controller with a touch panel allows you to program up to 10 different cutting thicknesses from one block in automatic mode.
Advantages of vertical cutting:
- High efficiency - hundreds of square meters per shift
- Precision ±1–2 mm with the knife in good condition
- Possibility of double-sided or single-sided cutting
- Automatic pneumatic knife tension
- Low operating cost
Method 2: Horizontal cutting with a band saw
Horizontal cutting machines DZIERGWA type PARK and PPAB cut thin sheets from the entire block. The cutting body moves horizontally on linear guides with ball bearings. Automatic pneumatic pressure stabilizes the material - cutting from 7 mm thick possible.
The belt conveyor automatically feeds and receives blocks, which is crucial in the continuous production of mattresses and sofa inserts.
Method 3: CNC contour cutting
Contour cutting machines DZIERGWA type KPO cut any 2D and 3D shapes using a knife or a heating wire guided by a CNC controller. Programming via devFOAM 2 software or DXF/SVG file import.
Applications: ergonomic pillows, shaped packaging, automotive components, orthopedic products, acoustic panels.
Method 4: Hot wire cutting
Steel wire heated to 200-400°C melts the foam, giving a smooth cutting surface. Wire thickness: 0.2–0.8 mm. Mainly used for foams up to 40 kg/m³ and complex 3D contours.
DZIRGWA string cutters of the KPA series are equipped with automatic wire tensioning and precise CNC control.
Method 5: Hybrid cutting
DZIERGWA hybrid machines type KPAH and HPA combine horizontal and contour cutting in one machine. Perfect for plants handling a variety of orders - without having to invest in two separate devices.
Method 6: Waterjet cutting
Used rarely - mainly for composite foams or when zero heat emission is required. The operating cost is much higher than with mechanical methods. Economically justified only for very specialized applications.
Method 7: CNC milling
CNC foam milling machines (DZIERGWA - pad milling machine) remove material by milling, creating recesses, grooves and profiles. Used in the production of seat pads, profiled mattresses and studio sound-absorbing panels.
How to choose a cutting method for your production?
- Straight slabs and blocks: PPA vertical or PARK horizontal cutter
- Thin sheets from 7 mm: PARK/PPAB horizontal cutter
- 2D/3D shapes: KPO contour cutter
- Complex 3D contours and mineral wool: KPA string cutter
- Large volumes, automation: CNC automatic machine with a conveyor
Doubts? DZIERGWA offers a free technical consultation - describe your material and requirements, and we will select the perfect machine for your production. Since 1997, over 800 machines in 19 countries.
Frequently asked questions (FAQ)
What is the fastest method for cutting foam in the production of mattresses?
The most efficient is horizontal cutting with a band saw (PARK) with a belt conveyor - automatic loading and unloading of the block shortens the production cycle to a minimum.
Does string cutting change the properties of the foam at the edge?
The thermally modified layer is 0.1–0.3 mm thick - practically negligible for furniture and upholstery applications.
Does DZIERGWA build machines to individual order?
Yes. Each machine is designed to meet specific customer requirements - table dimensions, cutting range, additional equipment. Contact us to discuss details.
Contact us — we'll be happy to advise and prepare an offer tailored to your needs!