Rebond Foam
ASTM D3574 Type I
Rebond Foam is bonded flexible-foam scrap: shredded chips pressed with adhesive binder under heat and pressure into dense blocks, supplied against ASTM D3574 Type I.
Reference datasheet — Rebond Foam is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the RB80 condition
Rebond Foam grades and fills
Rebond Foam is supplied in 8 conditions, soft to hard. RB80 is the default FabDigit quotes; the values on this page are for it.
Compare all 8 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
60 kg/m³ light rebond | Cheapest, softest rebond for void-fill packaging, light carpet underlay and non-structural padding. | 0.01 | 0.09 | 70 | 8 Shore A |
RB80Default 80 kg/m³ standard rebond | The stocked default: firm, cost-effective cushioning core, carpet cushion and mattress/furniture base layer. | 0.02 | 0.15 | 60 | 12 Shore A |
antimicrobial / low-odour treated rebond | Use for mattress, pet-bed and healthcare underlay where mildew, odour or bacterial growth in a humid environment is a concern. | 0.02 | 0.15 | 60 | 12 Shore A |
Flame-retardant rebond | Specify when the pad must pass furniture, transit or carpet-cushion fire tests; FR additive slightly stiffens the foam and adds cost. | 0.02 | 0.14 | 55 | 14 Shore A |
100 kg/m³ rebond | Pick for floor acoustic underlayment and firmer seating cores where deflection must stay low. | 0.02 | 0.19 | 55 | 15 Shore A |
120 kg/m³ rebond | Use where repeated heavy loading (commercial seating, equipment pads, tumbling mats) would bottom out lighter grades. | 0.03 | 0.23 | 50 | 20 Shore A |
150 kg/m³ rebond | High-density block for gym landing mats, crash pads and vibration-isolation bases. | 0.03 | 0.29 | 45 | 25 Shore A |
200 kg/m³ ultra-dense rebond | Choose for very high static loads, machinery isolation pads and anti-fatigue mat cores; nearly board-like feel. | 0.05 | 0.38 | 40 | 32 Shore A |
What is Rebond Foam?
Rebond Foam is bonded flexible-foam scrap: shredded chips pressed with adhesive binder under heat and pressure into dense blocks, supplied against ASTM D3574 Type I. It is the low-cost, high-density stock for underlay and cushioning cores, available as blocks, peeled roll goods and compression-moulded pads at about 0.08 g/cm³ with 0.15 MPa tensile strength and 60 % elongation. Properties vary with the chip mix, the surface is visibly heterogeneous, service tops out at 90 °C, and the cured thermoset cannot be welded or reprocessed. Virgin slabstock foam is the alternative where uniform cell structure or appearance matters. Rebond Foam has a density of 0.08 g/cm³ (0.0029 lb/in³), lighter than 87% of polymer grades. Its glass-transition temperature is -50°C (-58 °F). Rebond Foam has a yield strength of 0.02 MPa (0.0022 ksi) and a tensile strength of 0.15 MPa (0.0218 ksi) — weaker than 100% of polymer grades. Elongation at break is 60% and the elastic modulus is 8×10⁻⁴ GPa (1.16×10⁻⁴ Msi).
What is Rebond Foam used for?
- carpet underlay/padding
- gym and playground mats
- packaging dunnage
- furniture core stock
Advantages
- Low embodied carbon — 1.3 kg CO₂/kg, better than 100% of polymer grades
- Lightweight — 0.08 g/cm³ (0.0029 lb/in³), better than 87% of polymer grades
- Easy to machine — 80/100, better than 84% of polymer grades
- Forms and bends easily — 85/100, better than 81% of polymer grades
Limitations
- Low strength — 0.02 MPa (0.0022 ksi), worse than 100% of polymer grades
- Low stiffness — 8×10⁻⁴ GPa (1.16×10⁻⁴ Msi), worse than 98% of polymer grades
- Needs corrosion protection — 55/100, worse than 94% of polymer grades
- Degrades in UV without stabilisers — 20/100, worse than 88% of polymer grades
- Poor heat conductor — 0.05 W/m·K (0.026 BTU/hr·ft·°F), worse than 85% of polymer grades
Rebond Foam properties
Typical room-temperature values for Rebond Foam-RB80; bars are the position among polymer grades.
Physical2
Rebond Foam has a density of 0.08 g/cm³ (0.0029 lb/in³), lighter than 87% of polymer grades. Its glass-transition temperature is -50°C (-58 °F).
Mechanical11
Rebond Foam has a yield strength of 0.02 MPa (0.0022 ksi) and a tensile strength of 0.15 MPa (0.0218 ksi) — weaker than 100% of polymer grades. Elongation at break is 60% and the elastic modulus is 8×10⁻⁴ GPa (1.16×10⁻⁴ Msi).
Thermal7
Rebond Foam is rated for continuous service to 90°C (194 °F). It conducts heat at 0.05 W/m·K (0.026 BTU/hr·ft·°F), worse than 85% of polymer grades.
Electrical2
Rebond Foam has an electrical resistivity of 1×10¹⁰ Ω·m.
Chemical & Environmental3
Corrosion resistance is good (55/100), worse than 94% of polymer grades. UV resistance is poor.
Sustainability3
Producing a kilogram of Rebond Foam takes about 20 MJ of energy and emits 1.3 kg of CO₂ — less than 100% of polymer grades. Typical recycled content is 90%.
Manufacturability3
Rebond Foam's machinability is very good (80/100, better than 84% of polymer grades); weldability poor (15/100); formability excellent (85/100).
Common Calculations4
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the polymer family
Yield strength against density for every polymer grade FabDigit runs. Rebond Foam is highlighted; hover a dot for its name, or open the interactive family chart.
Working with Rebond Foam
Is Rebond Foam easy to machine?
Cut with band-knife, oscillating/drag blade CNC or hot-wire-free reciprocating saw; large cylinders are peeled into continuous roll stock — expect chip dust and blade dulling from the cured binder.
Can Rebond Foam be welded?
Not weldable as a thermoset; bond with contact/hot-melt PU adhesive or flame lamination to fabric and film.
Can Rebond Foam be formed, bent or molded?
Not injection moulded — chips plus MDI binder are steam-cured in a mould or cylinder press at roughly 100–130 °C, then cured/aged before cutting; compression moulding of profiled pads is common.
Rebond Foam chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| MDI prepolymer bindermoisture-cured polyurethane adhesive, steam-activated in the press | 5 – 12 | 8 |
| flame retardant (FR grades only)phosphate/phosphonate additive for CAL TB117 or FMVSS 302 | 0 – 5 | 0 |
| pigment / additivescolourant, antimicrobial, antistatic optional | 0 – 1 | 0.3 |
| recycled flexible polyurethane foam chipshredded scrap from slabstock trim, mixed colours | ≥ 85 (balance) |
What surface finishes work on Rebond Foam?
Usually left raw or laminated with scrim, nonwoven, film or fabric; no paint or plating — surfaces can be flame-laminated, glued or heat-embossed only.
Equivalent designations
Standards and trade names that resolve to Rebond Foam in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- D3574 Type I
How much does Rebond Foam cost?
Rebond Foam is a standard-cost polymer ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Rebond Foam — frequently asked
What is Rebond Foam used for?
Rebond Foam is typically used for carpet underlay/padding, gym and playground mats, packaging dunnage and furniture core stock. In short: lowest-cost high-density foam; recycled-content cushioning core; densest flexible PU stock.
What is the yield strength of Rebond Foam?
Rebond Foam has a typical yield strength of 0.02 MPa (0.0022 ksi) and a tensile strength of 0.15 MPa (0.0218 ksi) — weaker than 100% of polymer grades. Strength varies by condition: see the 8 listed tempers.
Is Rebond Foam easy to machine?
Yes — machinability is rated very good (80/100, better than 84% of polymer grades). Cut with band-knife, oscillating/drag blade CNC or hot-wire-free reciprocating saw; large cylinders are peeled into continuous roll stock — expect chip dust and blade dulling from the cured binder.
Can Rebond Foam be welded?
Not readily — weldability is rated poor (15/100). Not weldable as a thermoset; bond with contact/hot-melt PU adhesive or flame lamination to fabric and film.
What surface finishes work on Rebond Foam?
Usually left raw or laminated with scrim, nonwoven, film or fabric; no paint or plating — surfaces can be flame-laminated, glued or heat-embossed only.
Can Rebond Foam be formed, bent or molded?
Not injection moulded — chips plus MDI binder are steam-cured in a mould or cylinder press at roughly 100–130 °C, then cured/aged before cutting; compression moulding of profiled pads is common.
What is the maximum service temperature of Rebond Foam?
Rebond Foam is rated for continuous use to about 90°C (194 °F), and briefly to 120°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between Rebond Foam RB80 and Rebond Foam RB200?
RB80 is the default condition — the stocked default: firm, cost-effective cushioning core, carpet cushion and mattress/furniture base layer. RB200: choose for very high static loads, machinery isolation pads and anti-fatigue mat cores; nearly board-like feel. Yield strength is 0.02 MPa in RB80 versus 0.05 MPa in RB200.
How much does Rebond Foam cost?
Rebond Foam is a standard-cost polymer ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- ASTM D3574 — Standard Test Methods for Flexible Cellular Materials, Slab, Bonded and Molded Urethane Foams — ASTM International (2017)
- ASTM D3676 — Standard Specification for Rubber Cellular Cushion Used for Carpet or Rug Underlay — ASTM International (2018)
- California TB 117-2013 and FMVSS 302 flammability requirements — CA BEARHFTI / NHTSA (2013)
- Polyurethane Handbook (Oertel) and Gibson & Ashby, Cellular Solids — Hanser / Cambridge University Press (1997)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.