Foam Profiling Machine: Complex Profile And Geometry Machining By Compression — Fecken-Kirfel
Achieving consistent profiles in flexible or rebond foam — wave surfaces, reliefs, asymmetric shapes — requires a specific machining technology. FK profiling machines work by compressing the material to extract complex geometries with a precision and repeatability that simple cutting cannot achieve.
Our Fk Profiling Machines
The FK profiling machine range is based on the principle of compression profiling: the foam is compressed between profiled rollers before being cut by a band knife, which gives it its final shape upon release — a fundamentally different approach from cold roll forming or steel roll forming, and one specifically engineered for the unique elastic properties of foam and flexible materials.
These FK profiling machines operate on the same mechanical principle as a roll forming machine, but applied to foam rather than metal: material is fed continuously through a set of shaped rollers that progressively define the geometry, before the band knife sections the compressed profile at the exact point of maximum deformation. The result is a consistent, repeatable profile with no material waste.
The D 21 and D 31 models are the reference machines for profiling foam sheets up to 300 mm thick, including high-density foams. Their cast iron construction and specially formed band-knife beams deliver maximum robustness in production. The profiled rollers have a particularly large diameter — they withstand high pressures without deflecting, guaranteeing a consistent profile height across the full width of the sheet. The band knife adjusts automatically, maintaining a constant relationship between the material, the feed rollers and the blade throughout the full working life of the knife. The profiled rings are interchangeable, enabling fast changeover from one geometry to another in minutes.
The D 5 model extends this capability to three-dimensional profiles: symmetrical and asymmetrical moulded parts, mattress profiles, machining of polyether PU foam, polyester foam and rebond foam.
The Advantages Of Fk Profiling
Reproducible complex geometries: controlled compression produces identical profiles at every pass, with no dimensional drift across the production run — the core strength of this foam roll forming machine approach.
Zero material waste: the compression process optimises material utilisation — no offcuts are generated by profile machining, unlike conventional cutting methods.
Forming versatility: interchangeable profiled rings enable profile changeovers in minutes — no toolmaker required between production runs.
Convertibility: by replacing the profiled rollers with smooth rollers, the machine can also be used in standard horizontal splitting mode — two machines in one investment.
As the official French distributor of Fecken-Kirfel, Suteau-Anver supports you from machine selection through to installation, operator training and after-sales service, with spare parts available in stock for immediate dispatch.