Fusing PU foam spheres together

[FrankJaeger]

Hi everyone,

For this furniture project I'm doing I need to fuse ten PU Foam spheres together? I was wondering if there is a way to do this without using an adhesive? The spheres may deform in the process. The final result must look like tyrofoam but the scaled much bigger. Thanks!

 

[ornerynorsk]

I've never actually seen it done, but I have been told that PU foam can be high frequency welded. Very large parts with a lot of surface area are going to present limitations, though. Can your part(s) be molded one-piece instead of fabricating?

It is better to have enough ideas for some of them to be wrong, than to be always right by having no ideas at all.

 

[MikeHalloran]

Try inserting a hot blade between them, then pressing them gently together while withdrawing the blade. You may need more spheres to practice on...



Mike Halloran
Pembroke Pines, FL, USA

 

[FrankJaeger]

Thank you for the replies.

I like the idea with the heat. I wasn't sure if PU foam could be fused together using heat.