FOAM OR FIBER?

A Comparison of Fill Material

for Outdoor Cushioning

INTRODUCTION
For the average consumer and retail furniture buyer, navigating the world of cushion materials can be a
confusing proposition. With a technical community that continues to innovate, it is sometimes difficult to
differentiate which innovations create real value in terms of performance and customer experience and
which are just enhanced marketing. Polyurethane foam and polyester fiber remain the industry stand-
ards, yet the variety of choices that exist within these two options create a decision-making process that
is significantly more complex.

KEY PARAMETERS IN CHOOSING POLYURETHANE FOAM 1,2,3

Polyurethane foam has long been a staple of the cushion industry. Its excellent performance over
extended use coupled with a variety of types that can be tailored to specific applications allow retailers
to customize their offerings to individual markets.

When discussing the material in terms of outdoor performance, there are a few characteristics that
require some consideration. All flexible polyurethane foams have an open cellular structure which,
when applied in an outdoor setting, means that moisture can penetrate the body of the foam. While
polyurethane foam itself has antimicrobial properties, additional additives are often preferred for use
in outdoor applications in order to further protect against the effects of exposure to moisture. The other
two main performance elements to consider when reviewing foam are density and indentation force
deflection (IFD). Density, typically measured in pounds per cubic foot or kilograms per cubic meter, is
one of the key determining characteristics of a foam’s durability. A higher density rating will in most
cases equate to longer-term durability in the finished product. IFD refers essentially to the feel of finished
foam—i.e., the hardness or softness thereof. IFD is measured by the pounds of force required to indent
a piece of foam to 25% of its original thickness. Standard ranges are from five pounds (softest) to eighty
pounds (hardest).

Taking into account projected use and required longevity in the market, these criteria are key in
determining the appropriate foam type for a specific application.

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COMMON FOAM TYPES2
Standard foam
This is the most common type of polyurethane foam available. It is able to be
poured with a variety of densities and IFDs, making it a viable option for myriad
applications, both indoor and outdoor. In standard cushion applications, it can
provide the comfort, support and durability required.

High resiliency polyurethane foam

This foam type is almost identical to the standard foam in use and function, with
one key exception. It is created by using a higher grade of raw material and a
slightly altered process that makes the cellular structure of the finished foam more
random than that of standard foam. This has two distinct effects: first, this foam will
return to its original shape more quickly than a standard foam when compressed.
The second and perhaps more important effect is that this altered cellular structure
gives the foam a higher durability than its standard counterpart. This foam has a
clear use in high traffic situations where performance is required over an extended
or heightened period of use.

Dry fast or “reticulated” foam

This foam type is standard open cell foam which has had the cellular structure
exploded in order to create an open porosity visible to the naked eye. While other
foams in this category may retain moisture, the structure of reticulated foam has
been opened to an extent that it will pass directly through. The challenge with this
material is that, due to the volatility of the process used to make it, there is only a
limited offering in both density and feel (IFD). This foam is primarily used for outdoor
applications in the cushion industry as well as in the filtration industry.

Viscoelastic memory foam

This foam is also occasionally dubbed “slow recovery” foam. The key characteristic
of viscoelastic foam is that the cellular structure is more fluid, conforming to pressure
and returning to original form at a slower rate than standard foams. This makes it
ideal for use as a comfort layer in mattresses and other typically indoor furnishings. It
does, however, have a couple of challenges due to its structure: it is less supportive
than standard foams, and it is highly sensitive to heat and humidity (both of which
affect the recovery of the material and can limit its outdoor uses).4

New foam trends and technical developments: As mentioned earlier, the technical side of the foam
industry is ever evolving, which is giving the market access to new products all the time. A few of the most
exciting new developments are cool touch foams, mineral-infused foams and eco foam. Cool touch
foams are being heavily used in the mattress industry, as they have a less reactive structure to heat (both
in dispersion and the way heat influences the structural integrity of the material). Mineral infused foams
can give a foam mattress a lavender scent over an extended term of use (again, marketed toward
the mattress industry). Eco foams use plant-based chemicals as a portion of the raw material (versus
complete use of petroleum-based chemicals) for a more environmentally friendly, sustainable product.
While these are currently used predominantly in the indoor cushion and mattress industries, as the
technology continues to evolve so too will the range of uses.5

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KEY PARAMETERS IN CHOOSING POLYESTER FIBER 6,7
Polyester fiber has long competed with foam as the fill material of choice in the cushion industry—
particularly when it comes to outdoor applications. Not only is it typically cheaper than the foam
alternative, but its natural properties make it antimicrobial and moisture resistant.

When discussing fiber characteristics for any application, there are four traits that affect performance:

1. Denier, which equates to the thickness of the fiber. A thinner denier will have a softer feel,
whereas a thicker denier will have a coarser, robust feel.

2. Length of the fiber, which affects how the fiber fills out the covering and how much fiber is
required to meet the finish.

3. Crimp of the fiber, which speaks to the number of bends put into each strand of material.
The crimp is particularly relevant in blown applications where more highly-crimped fibers have
a higher resilience.

4. Conjugation of the fiber, or twist, which adds to the fiber’s resilience.

Additionally, fibers come in several classifications dependent on the base material—for example, virgin,
semi-virgin or recycled, which speak to the amount of recycled material included in the finished fiber.
Many recycled materials can come close to the performance of the virgin (new) material; however,
virgin material will have the overall best durability and feel.

COMMON POLYESTER FIBER FINISHES 6,7

Blown polyester
Often, raw polyester fibers are mixed and blown into casings as a fill material for
pillows. This is a common alternative to down pillows or shredded polyurethane
foam. Additionally, some of the more expensive low-denier virgin materials
(down alternative) can very closely imitate the feel and function of down while
maintaining the properties that make it ideal for outdoor use. While this virgin
material is somewhat more costly than the recycled options in the market, a
wide variety of feels and finishes can be provided by each for use as pillows
or cushioning.

Thermal bonded batted polyester

Thermal bonded batted polyester consists of polyester fibers which go through
a mixing, layering and heat treating process to create a substitute product for
polyurethane foam. This material can be layered to a variety of densities and
thicknesses to emulate the properties of foam. While this material is cheaper than
foam options and does not retain moisture as many of the foam options can, it
suffers from a lower durability than comparable foam options. This is an important
consideration when weighing it against foam as a fill material for cushions,
dependent on the expected life cycle of the finished good.

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COMPARISON BETWEEN FOAM AND FIBER USE
When finally comparing polyurethane foam versus polyester fiber applications, particularly for outdoor
use, note that it is possible to create a high-performing and durable product using either. The key is
matching the performance expectation, environmental expectations and required finished feel and
aesthetic with the appropriate material.

FILL MATERIAL DECISION MATRIX

Moisture Microbial Market

Durability Cost Notes
Resistance Resistance Applications

Standard Furniture Widely used industry

Polyurethane Good Good Better Mid cushioning, standard for cushioning
Foam Insulation and upholstery

High
Furniture Used widely in contract
Resilience
Good Good Best Mid-High cushioning, and commercial
Polyurethane
Insulation furniture applications
Foam

For cushioning, used

Dry Fast or Furniture primarily in outdoor
Reticulated Best Best Better High cushioning, applications due to
Foam Filtration moisture resistance
and weathering

Widely used in the

Primarily
bedding industry;
Viscoelastic indoor
limited outdoor
Memory Good Good Good High furniture
applications due
Foam cushioning,
to temp and
Mattresses
humidity sensitivity

Current main uses are

Specialty Primarily
Variable Variable Variable High in the indoor furnishing
Foams mattresses
and bedding industries

Blown Great alternative

Polyester Better Better Good Low-Mid Pillows to down as a
Fiber pillow material

Lower cost alternative

Batted Furniture to foam for
Polyester Better Better Good Low cushioning, cushion seating
Fiber Insulation and items requiring
added support

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CONCLUSION
The number of options for cushion fill material can be daunting. Understanding the market, environment
and customer expectations is critical to wading through the plethora of options available. With our
experience in the development and fabrication of multiple fill programs, Easy Way Products can work
with you to select the ideal fill material for your application. This service, in conjunction with our robust
supply chain, allows our customers to bring a variety of high performance outdoor furnishing options to
the retail consumer.

REFERENCES
1. American Chemistry Council “Polyurethanes”, January 19th , 2016 http://polyurethane.
americanchemistry.com/Introduction-to-Polyurethanes

2. Polyurethane Foam Association (PFA), January 19th , 2016 http://www.pfa.org

3. Joint Industry Foam Standards and Guidelines: “Indentation and Force Deflection (IFD) Standards
and Guidelines”, July 1994 http://www.pfa.org/jifsg/jifsgs4.html

4. “The effects of moisture absorption on the physical properties of polyurethane shape memory
polymer foams”, August 1st , 2011 http://www.ncbi.nlm.nih.gov/pmc/articles/PMC3176498/

5. Foam Partner, January 19th, 2016 http://www.foampartner.com/en/

6. Stein Fiber, January 19th , 2016 http://www.steinfibers.com/

7. Textile Learner Blog “Polyester Fiber” January 19th , 2016 http://textilelearner.blogspot.

com/2011/07/polyester-fiber-characteristics-of_11.html

Easy Way Products is the premier provider of lifestyle furnishings for the retail market. From cushions
and pillows to table runners and drapes, we work with you to create unique and beautiful designs to
complement your outdoor furniture lines.

For more information about our fill programs and other manufacturing capabilities, give us a call
at (513) 731-5640.

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