Author Topic: Cordura Laminated to Foam  (Read 498 times)

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Gear Dynamics

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Cordura Laminated to Foam
« on: July 19, 2018, 07:37:49 PM »
Looking for Cordura laminated to closed cell foam, ideally finished on both sides of the foam, but single side might be OK too. 1/8" foam would be preferable and something in the 400D-500D Cordura range, in a neutral colour.

Thanks!

Stone

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Re: Cordura Laminated to Foam
« Reply #1 on: July 19, 2018, 08:22:31 PM »
Are you looking for a readymade source, or methods of construction? Closed cell foam is a pretty broad brush, as there are different densities of CCF to choose from.

If looking for a ready made source, vs DIY, you'll most likely be looking at high minimums to make it justifiable price-wise. But not much flexibility in terms of options on colors and/or patterns.

Just my 2c

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BOgear

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Re: Cordura Laminated to Foam
« Reply #2 on: July 20, 2018, 12:37:10 AM »
We struggled with this here in Australia so had to resort to doing it in house. We couldn't find anyone who did it or offered it as a service.

This is how we did it: http://www.bogear.com.au/blog/manufacturing-process-spray-lamination/

If you DIY, I highly recommend doing in a batch of 10 or more sheets at a time (our sheets were 1.3m x 1m from memory). The biggest time suck is setting up and packing down. By spreading the work among a bigger batch you help drive down the cost per unit.
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Gear Dynamics

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Re: Cordura Laminated to Foam
« Reply #3 on: July 20, 2018, 08:53:02 PM »
I was looking for a premade solution. We have dozens of samples of foams hear, and our current foams are good for the current process. Iím not sure we are at the stage where I want to set up an operation like this in the shop. Right now we are using a PSA that is on a roll. Itís fairly straight forward, but not ideal for complex designs. Itís also quite expensive, so any wasted material is a pain. Iím intrigued about other options to laminate fabric to foam, so Iím all ears if people have suggestions.

BOgear, Iíve seen your video before and your process looks pretty easy. Iíve got some questions for you:

1. What is the adhesive that you are using and how expensive is it?
2. How does the laminated product like repeatedly being exposed to water?
3. For your face fabric, you mention using Cordura, is it PU coated? Any issues with adhesion?
4. Once you have your laminated sheets, what method of construction do you use to make the rest of the shoulder strap?

The purpose of all of this is that Iíd like to tweak our harness and rig panels, so the assembly time is reduced, and we can possibley discontinue the need for stocking expensive PSA rolls.




Corvus

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Re: Cordura Laminated to Foam
« Reply #4 on: July 23, 2018, 02:04:53 PM »
I was just looking for the same. Here are a few I found:

http://www.rockywoods.com/1050-Denier-Black-Nylon-CORDURA-Two-sided  1050d on both sides of foam

http://www.rockywoods.com/600-Denier-0.25-Black-Polyester-DWR-Urethane-Coated-Laminated-to-Foam-Black-Tricot-Backing  600d on one side, tricot on the other.

Thee was also a 1000d in hunter green I think.

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Gear Dynamics

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Re: Cordura Laminated to Foam
« Reply #5 on: July 23, 2018, 09:50:11 PM »
Iíve seen the rockywoods ones. Open cell foam though...

Stone

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Re: Cordura Laminated to Foam
« Reply #6 on: July 24, 2018, 11:51:25 PM »
Why not just use contact adhesive, such as those used by automotive trimming shops? Dapper Landau or another solvent-based adhesive should do the trick.

Now, are we talking single items being built to order here, or larger runs being done at the same time? The 3M spray adhesives such as super 90 have proved to be very resilient to both heat and time in my experience, but costs do add up with this method of working in large quantities, along with proper ventilation requirements. I just spray outdoors.

-Dan

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Re: Cordura Laminated to Foam
« Reply #7 on: July 25, 2018, 10:50:35 PM »
The purpose of this post was to explore options of removing the lamination process from our assembly steps. At present, all rigs are made to order, and at any given time there might be two or three being made. However, we are looking for ways to expedite the assembly process, so having a premade solution would be ideal.

If we were going to use a contact adhesive, weíd do a setup like BOgear has. The 3M sprays in a can are mediocre and getting a good adhesion entirely depends on the foam youíre using and the coatings on the fabric. Weíve tried the Super 77 and the Hi-Strength 90. Neither bonded well.

rouge

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Re: Cordura Laminated to Foam
« Reply #8 on: July 29, 2018, 06:29:44 AM »
Ive steered away from using craft glues
Ive started going to diy stores and using carpet glue, i think they use it to adhere carpets to the stuff that goes underneath them, this stuff is great but is very overpowering, i actually have to go outside and wear a longsleeve t-shirt as it makes my arms itch and burn