How is Memory Foam Made?
First developed in 1966 for NASA's research programme, memory foam has been on quite a journey since. It was originally created to improve the safety of aircraft cushions and was previously known as "slow spring-back foam" and "temper foam". That history is why many consumers first met memory foam through the memory foam mattress brought to the mass market by Tempur.
What is memory foam?
Memory foam first reached the commercial market in 1991. It's a viscoelastic material made from a specialist combination of chemical compounds, also known as low-resistance polyurethane foam. Its cells allow air to move between them, giving the slow, elastic feel, and higher-density memory foams react to body heat so the foam moulds to an accommodating shape in a short time. The exact chemical formulation is a closely guarded industry secret, but manufacture follows a standard common process.
How memory foam is made
The starting component is polyurethane, blended with two groups of petrochemicals known as monols and polyols. An exothermic reaction begins as these combine into a liquid; the chemicals aid flexibility and, combined with calcium carbonate, develop the optimum mixture thickness. The mixture is gently warmed until the ingredients melt, then whipped to incorporate air – important for the material's springy nature.
Polyurethane is the main chemical component of memory foam and is largely responsible for the reactions involved, as it's made from polymer compounds that react with water and, with an appropriate catalyst, form cell-like shapes that trap air. Surfactants then continue the reaction in a controlled way, ensuring the bubbles develop to a regulated size.
At the right consistency the mixture resembles a malleable soft dough, and it must be at the correct temperature to pour into its mould. Because the blend is chemically fragile, it's dispensed at a specific rate so as not to disrupt the reaction – otherwise the foam won't form with the desired shape, springiness or make-up. Once in the mould, the air is pumped out at high pressure to form the open-cell structure. After quick drying and cooling, the foam slabstock is removed, washed, dried and quality-checked, before being cut into smaller components such as mattresses – the end of an eight-hour process on average.
Memory foam vs polyurethane foam
The main difference between making polyurethane foam and memory foam is the unique selection of chemical compounds mixed together. Memory foam's development differs through the addition of hydrocarbons to the mixing process, but the method is largely the same. For the wider story, see our guides to polyurethane foam history and our memory foam facts.
At eFoam, we pride ourselves on our specialist cut to size services and bespoke products, with an extensive range of foam types to match every customer. To speak with a friendly, knowledgeable adviser, please contact us.
Frequently asked questions
Who invented memory foam?
Memory foam was first developed in 1966 for NASA, to improve the safety of aircraft cushions. It was originally known as "slow spring-back foam" and "temper foam". It became commercially available in 1991 and was popularised in mattresses by Tempur.
What is memory foam made of?
Memory foam is a viscoelastic, low-resistance polyurethane foam made from a specialist combination of chemical compounds. Polyurethane is the main component; its cells allow air to move between them, giving the slow, elastic feel, and higher-density versions react to body heat to mould to shape.
How long does it take to make memory foam?
On average, the production process takes around eight hours. The chemicals are mixed into a dough-like consistency, poured into a mould at a controlled rate, then air is pumped out under high pressure to form the open-cell structure before the foam is dried, cooled, washed, checked and cut.
