Reconstituted Foam (Chip Foam): Uses, Grades & Benefits

Reconstituted foam is a hard-wearing, recycled foam made by compacting and bonding together leftover pieces of polyurethane foam. This guide covers what it is, what it's used for, the grades available, and why it's such a cost-effective choice.

What is reconstituted foam?

Reconstituted foam (sometimes called chip foam or crumb foam) is a unique foam type made up of pieces of leftover polyurethane foam – offcuts and remnants from cutting foam to size – that have been compacted and bonded together. The result is a surprisingly resilient, firm product with a long lifespan. Visually it looks multi-coloured and marbled, because of all the different pieces of foam used to make it, which vary in size and colour.

What is reconstituted foam used for?

It is generally best for applications that get a lot of use, such as pub seating, public transport seating, gym mats, crash mats and church kneelers. It can also be used for packaging and sound insulation. This high-density chip foam can be cut to any size or shape and made into sheets, and is sometimes used together with new foam – for example, a reconstituted cushion can have a top layer of new foam for a little more comfort.

Grades and weights

Reconstituted foam comes in different weights and strengths, usually a 6 pound per cubic foot grade (SFR6) and a heavier, denser 9 pound grade (SFR9) for more demanding applications. You can see how it compares with the standard upholstery foam grades in our first-time buyer's guide to foam cut to size.

Why choose reconstituted foam?

Being a recycled product, reconstituted foam is also cost-effective. It is good to know that the foam industry can make such good use of leftover foam pieces and offcuts rather than throwing them away, turning them into a sturdy product with a long lifespan.

Frequently asked questions

What is reconstituted foam?

Reconstituted foam, sometimes called chip foam or crumb foam, is made from pieces of leftover polyurethane foam (offcuts and remnants) that have been compacted and bonded together into a resilient, firm product with a long lifespan.

What is reconstituted foam used for?

It is best for heavy-use applications such as pub seating, public transport seating, gym mats, crash mats and church kneelers, and can also be used for packaging and sound insulation.

What is the difference between 6lb and 9lb chip foam?

Reconstituted foam comes in different weights. The 6 pound per cubic foot grade suits most uses, while the heavier, denser 9 pound grade is made for more demanding applications.

Is reconstituted foam environmentally friendly?

Yes. It is a recycled product made from leftover foam pieces and offcuts that would otherwise be discarded, which also makes it cost-effective.