Aerofoam Ltd Brand Loader
Aerofoam Ltd Healthcare Foam Mattresses

At Aerofoam Ltd, we understand that in the healthcare sector, foam does much more than provide comfort it plays a critical role in patient care, recovery and pressure ulcer prevention. We convert high-specification medical foams into finished and semi-finished components for healthcare providers across the UK.

From standard hospital ward mattresses to high-risk anti-decubitus modular systems, we offer a comprehensive range of intelligent foam solutions. Our advanced CNC profile cutting allows us to create castellated (cast-cut) mattresses that respond to patient movement and distribute weight evenly.

Our Medical Foam Capabilities

  • Pressure Relief Mattresses

    Multi-layered and CNC castellated foam cores designed specifically for varying risk levels of pressure sores (from low to very high risk).

  • Wheelchair & Postural Seating

    Ergonomically contoured foams that provide crucial pelvic support, stability and pressure distribution for long-term wheelchair users.

  • Patient Positioning Aids

    Wedges, abduction blocks and heel supports manufactured from firm, supportive foams to assist in patient positioning during surgery or recovery.

  • Viscoelastic (Memory) Foam Layers

    Temperature-sensitive foams used as top layers on mattresses and cushions to mold to the body's contours and reduce shear friction.

  • Reticulated Filter Foams

    Open-pore foams utilized in specialized medical devices, negative pressure wound therapy (NPWT) and fluid filtration.

Stringent Quality & Compliance

  • All foams meet strict Crib 5 / Source 5 UK fire regulations
  • Anti-microbial and hypoallergenic foam options available
  • Consistent batch-to-batch quality control
  • Traceability from foam block to finished product
  • Expertise in bonding and laminating complex multi-zone cores

Require reliable, compliant medical foam components?
Contact Aerofoam to discuss your healthcare foam manufacturing needs.

Get Started

Request a Quote or Sample

Tell us your requirements and our team will respond within 24–48 hours with a tailored solution.

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FAQs

Frequently Asked Questions

What is a castellated mattress?

A castellated (or cast-cut) mattress has a grid of square or rectangular cuts across the top layer of foam. This allows the foam to move independently, reducing shear and friction on the patient's skin and significantly improving airflow.

Do you supply waterproof medical covers?

Yes. While we primarily convert the foam cores, we also supply fully finished mattresses featuring welded or stitched vapour-permeable, waterproof and antibacterial covers that comply with infection control protocols.

What foam densities do you use for healthcare mattresses?

We use highly resilient CMHR (Combustion Modified High Resilience) foams for the core base to provide longevity and structural support, often topped with softer, lower-density viscoelastic (memory) foam to maximize pressure redistribution.

Are your medical foams fire safe?

Absolutely. All foams supplied for healthcare environments are manufactured to meet stringent UK Crib 5 (Source 5) or Crib 7 fire safety regulations.

Can you manufacture bariatric mattresses?

Yes. We can engineer bespoke multi-layer foam mattresses using ultra-high-density foams specifically designed to support higher weight limits without bottoming out, ensuring comfort and pressure relief for bariatric patients.