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Filter Foam

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New England Foam supplies, converts & fabricates the following types of filter foam:

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Types of Polyester Filter Foam Available

10-PPI-Polyester-Filter-Foam-Sheets 20-PPI-Polyester-Filter-Foam-Sheets 80-PPI-Polyester-Filter-Foam-Sheets 90-PPI-Polyester-Filter-Foam-Sheets  
10-PPI-Black-Polyester 20-PPI-Black-Polyester 80-PPI-Black-Polyester 90-PPI-White-Polyester    
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Types of Polyether Filter Foam Available

20-PPI-Polyether-Filter-Foam-Sheets 30-PPI-Polyether-Filter-Foam-Sheets 40-PPI-Polyether-Filter-Foam-Sheets 50-PPI-Polyether-Filter-Foam-Sheets    
20-PPI-Black-Polyether 30-PPI-Black-Polyether 40-PPI-Black-Polyether 50-PPI-Black-Polyether    
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Characteristics of Filter Foam

Filter foam, also known as reticulated foam, is a porous, low-density type of polyurethane foam with an open cell structure. Filter foam has a near-infinite amount of applications due to the following characteristics:

  Characteristics of Filter Foam
  • Compressibility
  • Cushioning
  • Energy absorption
  • Fabricatibility
  • Flexibility
  • Light-weight
  • Low thermal conductivity
  • Low water vapor transmission
  • Mildew-resistance
  • Resiliency
  • Sound absorption
  • Vibration dampening
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Filter Foam Available

Filter foam is the ideal material for applications where porosity, surface area & low-density are integral for success.

In addition to fabricating filter foam products to custom designed specifications, New England Foam stocks filter foam in bun, roll & sheet forms, in porosities ranging from 10 PPI or pores per inch (coarse) to 100 PPI (fine) & those colors most requested: charcoal (black) & white.

Additional porosities & colors are available upon request, as well as Underwriters Laboratory (UL) compliant filter foam.

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Filter Foam's Cell Structure


Filter foam operates as a depth-loading filter, as opposed to a surface-loading filter, essentially trapping dust particles within its cells.

The cell structure of filter foam is remarkable in that each cell has a dodecahedron shape (12 sided), the cell’s walls or “struts” are comprised entirely of organic polymers (polyurethane, polyether, polyester) & the empty space or “windows,” between each strut, comprise 95% - 98% of the filter foam’s mass.

The size, shape & distribution of cells within filter foam can be manipulated during manufacture to provide precisely the desired porosity level, measured in PPI or pores per inch.

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Polyester Filter Foam vs. Polyether Filter Foam

In applications where the filter foam will come into contact with a liquid-based solution, the filter foam should be manufactured with polyether-based polyols.

In applications where the filter foam will come into contact with gases, such as oxygen, nitrogen &/or carbon dioxide, the filter foam should be manufactured with polyester-based polyols.

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Manufacturing Filter Foam


Filter foam can be manufactured using a thermal process where a preformed block of conventional polyurethane foam undergoes the removal of space from between each cell wall or “strut.”

Penetrating the internal structure of the filter foam with a combustible gas, such as hydrogen, & then igniting the gas in a controlled explosion accomplishes the removal of the thin layer of foam between each cell's membrane.

The result is freshly manufactured filter foam that is perfectly porous & ready for further fabrication.

It is during this manufacturing process that flame retardant additives can be introduced to the filter foam to meet various fire code standards.

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