Flame Lamination
Flame Lamination: Strong, seamless bonding without adhesives
Flame lamination is a high-precision thermal bonding process in which an open-cell foam layer is momentarily surface-melted and immediately pressed to a substrate textile. The molten foam forms a uniform polymer interface with the fabric, producing a high-strength mechanical and chemical bond without introducing external adhesives.
Benefits of flame lamination include:
- Strong, long-lasting bonds
- No added adhesives or chemicals
- Clean, smooth finish
- Cost-effective for large-scale production
- Ideal for curved or complex shapes
- Compatible with a wide range of materials
- Reduces material waste
- Improves product durability and comfort
Multi-Layer Lamination
As part of our flame lamination capabilities, AFL Group offers both bi-lamination and tri-lamination processes to enhance textile stability and performance.
These techniques involve adding a Cerex or Denier backing to the material, improving its structural integrity and allowing it to better hold needle thread during final fabrication. This results in cleaner stitching, improved durability, and greater consistency across finished products.
Common lamination combinations include:
- Polyurethane to fabric
- Polyurethane to vinyl
- Polyethylene to foam (single or double layers to build thickness)
- Geonet to geotextiles
Whether you're producing automotive interiors, industrial textiles, or custom foam assemblies, our lamination solutions are tailored to meet your exact specifications.
Flame Lamination applications
Flame lamination is widely used across industries that require strong, flexible and durable bonding between foam and textiles. Its adhesive-free process makes it ideal for high-performance products where clean finishes and long-lasting durability are essential.
Common applications include:
- Automotive interiors
- Furniture and general upholstery
- Medical and rehabilitation products
- Acoustic and thermal insulation
- Outdoor gear and equipment
- Packaging and protective inserts
- Marine cushions and covers
- Apparel and padded accessories
- Industrial textiles
- Military equipment
Contact AFL Group today to discuss your project and discover how our flame lamination services can deliver precision, durability, and efficiency.
Why choose AFL Group for Flame Lamination?
Flame lamination is a highly effective method for bonding foam to textiles, creating durable, flexible, and high-performance composite materials. Here’s why AFL Group is the trusted choice for flame lamination:
Specialised Expertise
We have extensive experience in flame lamination, ensuring strong, consistent bonds across a wide range of materials.Advanced Equipment
Our modern lamination machinery delivers precise heat control and uniform bonding for superior product quality.Custom Lamination Solutions
We tailor each job to your specific material and application needs, whether for automotive, medical, furniture, or industrial use.Consistent Quality Control
Every project undergoes strict monitoring and testing to guarantee uniform results.Local Manufacturing Advantage
As an Australian-owned and operated business, we offer fast turnaround, responsive service, and alignment with local standards.Integrated Services
Combine flame lamination with our CNC sewing and pattern cutting capabilities for a complete production solution.Eco-Conscious Approach
We aim to reduce waste and use environmentally responsible practices throughout our lamination process.Reliable Partnerships
We’re committed to building long-term relationships through dependable service, clear communication, and consistent results.For some composites, a very thin layer of foam can be used as a bonding agent between two materials, taking advantage of the desirable characteristics of flame lamination, without adding any appreciable thickness.