What is a Horizontal Foam Cutting Machine?

A horizontal foam cutting machine slices foam blocks into sheets of specific thicknesses. Its primary difference from vertical cutting machines lies in the direction of its ring-shaped band knife, which operates horizontally at high speed.

To prevent the foam from shifting during cutting, vacuum suction plates (with a vacuum level of about 800Pa) are often installed beneath the conveyor belt or worktable to secure the foam in place. Additionally, a pressing roller may be installed above the foam near the band knife’s pressure plate. This roller maintains pressure on the foam and rotates at the same linear speed as the conveyor belt to prevent lifting during cutting. This setup is especially suitable for cutting high-density or bonded foam blocks.

Horizontal cutting machines come in various forms, classified by the movement of the cutting head’s frame: fixed-frame and sliding-frame types. Foam block conveying methods include sliding table, conveyor belt, and rotary table systems. The following are different machine types:

(1) Conveyor Belt and Sliding Table Type Horizontal Cutting Machines

These machines use a conveyor belt or sliding table to transport foam blocks to the cutting knife. After each cut, the conveyor or table returns to its original position, and the knife automatically lowers according to the selected thickness. This process repeats until cutting is complete.

Sliding table machines are typically used for shorter foam blocks (up to 10m), while conveyor systems are preferred for longer blocks (up to 45m or even 60m), requiring workspaces as long as 125m.

Conveyor-based machines can be connected with additional feeding and unloading systems to form integrated production lines, improving efficiency by reducing foam transfer time between machines. When combined with bonding and automatic roll-up devices, 10m foam blocks can be processed into rolls up to 1.5m in diameter.

Cutting speeds range from 10–70 m/min, depending on the foam’s thickness and density. For high-density foam, speeds of 5–50 m/min are typical. Maximum block width is 2.5m, height is 1.5m, and minimum sheet thickness is 2mm.

(2) Mobile-Frame Horizontal Cutting Machines

In this type, the foam block remains stationary while the cutting frame moves. It is mainly used for slicing long foam blocks (often 50–60m) into thin sheets. The cutting frame travels on rails, which must be precisely manufactured and installed to ensure stability and accuracy. These machines offer cutting speeds up to 120 m/min and can slice down to 2mm thickness.

(3) Circular Foam Cutting Machines

These machines rotate foam blocks on a turntable for slicing and are mainly used for short blocks. Unlike reciprocating machines, circular cutting machines eliminate unnecessary "return" movements. After one complete rotation and cut, the knife simply lowers for the next cut, allowing for continuous operation and improved efficiency.

The turntable is driven by a variable-speed motor, rotating at 0.5–5 r/min, with diameters up to 9m and cutting speeds of 75–100 m/min. The foam can be secured with vacuum suction or its own weight. These machines are commonly used for thin sheets with a minimum thickness of 1.5mm.

(4) Ring-Type Cutting Machines

Ring-type cutting machines are highly efficient for long foam blocks and function like conveyor cutting production lines. They consist of a circular transport system, cutting head, block positioning system, edge trimming, automatic roll-up units, and padding material feeding/cutting mechanisms .

These machines move the foam in a single direction, eliminating reverse movement and boosting efficiency. The cut foam sheets are uniform in quality, making this ideal for long thin sheets. Cutting speeds range from 0–140 m/min. For continuous cutting, foam block ends can be glued to form a loop, enabling short blocks to yield longer sheets. Sheet thickness is controlled by coordinating conveyor speed with blade descent speed.

Standard ring cutters support block lengths of 50m, 60m, 100m, and 120m, with cutting heights of 950mm or 1250mm. "Mini" versions handle 20m blocks.

Despite their advantages, ring-type cutters are expensive and require significant space and storage systems for long foam blocks, which may limit adoption. However, they are an attractive solution for factories needing high volumes of long foam sheets.