Risk:
Lots of low quality foam is made overseas in Asian factories that
have much less stringent regulations for consumer protection. Some
of these manufacturers use dangerous chemicals like formaldehyde in
the manufacturing process which can cause allergic reactions and/or
unpleasant smells.
How To Avoid It: Buy from a reputable American manufacturer
that does not use dangerous chemicals to produce their foam.
Risk:
Many of these manufacturers produce foam in what are essentially large
cookie sheets. Liquid foam is poured in and allowed to settle as it
cures. This produces inconsistencies in density, as gravity acts on
the foam, drawing more material to the bottom. The result is foam
with unpredictable densities; foam that is labeled as having a “4
pound density” may really only be 3 lbs. There are even some high-priced
“mall brands” that still use this outdated process.
How
To Avoid It: Buy from a manufacturer using more advanced
processes. A few manufacturers, like Sleep Aid, are using a more
modern production technique called vacuum injection. Liquid foam
is injected into a sealed vacuum chamber, counteracting the effects
of gravity, and thereby ensuring a consistent density of foam. This
process also greatly reduces the fumes and “off-gassing” associated
with production, and that’s good for our environment.
Risk:
Cheap foam breaks down rapidly, sometimes flaking and crumbling before
it even leaves the shelf. This is simply a result of low-quality
materials and low-tech production techniques.
How To Avoid It:
Buy from a reputable company! High quality foam will last upwards
of ten or twenty years. Low quality foam can break down in a matter
of weeks. It’s worth paying a little more to ensure that you receive
a durable, high-quality product.