From upholstery to costume construction, closed cell foam has many uses. Its flexible nature and insulating properties make it useful in virtually all walks of life. From seat cushions and protective foam inserts, it is found in thousands of places. The best way to join foam to foam or foam to fabric is with adhesive products. There are many different foam adhesives on the market, and using them takes a little practice.
Cut all edges and faces to be joined as smoothly as possible. Measure carefully to make sure that pieces fit each other properly for best results. Make sure that the surfaces are all clean and free from dust, oil and moisture. Work in a space that fits the manufacturer's recommendation for temperature, as cold air will affect the adhesive's ability to bond.
Use a spray adhesive, such as Super 77 from 3M, to join the foam pieces together. Always use spray adhesives in a well-ventilated area. Apply an even coat to both pieces to be joined. Make sure that the entire surface of the joint is covered. Allow the adhesive to set for one to three minutes to provide the best tack. Experiment with scrap pieces before joining project pieces.
Attach the glued faces directly to each other. Avoid contact with other surfaces to prevent damage to the foam. Hold the foam in place until the adhesive sets. Use clothespins or spring clamps to hold pieces together. Leave the joint clamped together for a minimum of 10 minutes before testing the joint for strength.
Attach fabric to foam by following the same procedure. Be careful not to allow the fabric to fold over on itself. Stretch it out fully over the foam and lower it into position, being careful to avoid wrinkles. Press the fabric smoothly onto the foam. Allow it to set up fully before cutting the edges. Attach foam to wood, paper or cardboard in the same manner.