Case study: High-End Headphones: Audio Foam

During the design period, their advice was invaluable, saving us time and enabling is to develop a quality product at a commercial price.

 

mr gorecki foam engineer

The client

High-end audio equipment manufacturer

The challenge

DJ headphones pose a real challenge for manufacturers. Like all headphones, they must be comfortable to wear for extended periods while having high noise-cancelling properties for use in loud nightclubs and home studios.

As such, our client wanted to introduce a range of headphones that were very soft, but also had sound-deadening foam.

Unfortunately, sound-deadening foam is high-density, and therefore heavy, firm and not soft. While effective, it would be uncomfortable to have hard foam pressed against your ears for a long time.

The challenge was to come up with a low-density foam that effectively absorbed sound.

 

The challenge was to come up with a low-density foam that effectively absorbed sound.

Our solution

We spoke to our network of suppliers and identified a low-density polyurethane foam from a specialist in the USA.

The foam had a consistent cell structure, which meant it effectively absorbed sound and was also soft.

 

How it worked

Our client explains: “Our decision to appoint Technical Foam Services was based on their knowledge of suitable foam grades available from their global manufacturing partners, as well as their in-house production conversion capability.

Our customer’s DJ headphones were soft and sound-deadening. They fit around the ears, killed external sound and were covered with a permeable vinyl, so they could be wiped clean.

During the design period, their advice was invaluable, saving us time and enabling is to develop a quality product at a commercial price.”

 

Our decision to appoint Technical Foam Services was based on their knowledge of suitable foam grades available from their global manufacturing partners, as well as their in-house production conversion capability.

 

 

The results

As DJ headphones, they needed a professional spec and without our foam, they wouldn’t have met that.

At the time, our customer said: “This project was a great success and we will certainly work with Technical Foam Services on any foam-based products in the future.”

And they have.

Since then, we have built a great working relationship based on trust, expertise and great communication. Today we continue to work with the company on a number of products and components 10 years on.

 

Get in touch today to discuss your project. 

10 Year

client relationship

If you want any more information or have questions about Technical Foam Services, why not give us a call?

+44 (0)1536 443000

For all new enquiries
Contact our Sales Manager, Ross Thurlow:

Email Ross

Or call Ross directly at: +44 (0)7718 619250