Cushioning

Cushioning refers to materials and structures designed to absorb energy, reduce impact, and provide comfort or protection. It is used across industries, from consumer products such as seating and footwear to packaging, automotive, and medical devices. The goal is to minimize transmitted forces, distribute pressure, and dampen vibration.

Common cushioning materials include foams (polyurethane foam, memory foam, latex foam), rubber, silicone, gel packs, air-filled bladders, and fiber-based battings. In packaging, cushioning often consists of bubble wrap, air pillows, molded foam, foam-in-place systems, or molded pulp, designed to fill space and dampen shock. Performance depends on density, elasticity, compression set, and resilience; different applications require different trade-offs between softness and support, weight, cost, and heat or moisture resistance.

Applications include seating and bedding for comfort and posture; athletic footwear and sports equipment for impact protection; automotive interior components and safer crash energy management; medical devices and pressure-relief systems to prevent ulcers; electronics enclosures to shield delicate components. Design considerations include durability, hygiene, temperature sensitivity, recyclability, and regulatory compliance.

Environmental and sustainability aspects: some foams are challenging to recycle; increasing use of reclaimed materials, bio-based alternatives, and closed-loop recycling. Manufacturing methods include foaming, extrusion, and molding; advances aim to improve energy absorption per unit weight and reduce environmental impact.