Production and conversion of EVA foams for orthopedic footwear technology and medical technology
Afros Schaumstoffe GmbH
Pirmasens (Karolinenstr. 23)New on Amplifa
About Afros Schaumstoffe
Afros Schaumstoffe GmbH, based in Pirmasens, specializes in the development, production and conversion of foams used mainly in orthopedic footwear technology and medical technology. The company develops its own formulations for microcellular cross-linked EVA foams and offers them as milling foams, cushioning materials, build-up materials and cover materials, including the product lines Litelon EX, Litelon KX, Biolon, Flexolon, Litelax and LiteSteam. Production encompasses foam manufacturing according to in-house formulations, custom conversion, cutting and laminating, through to die-cut parts and foot-shaped blanks for the CNC milling of orthopedic insoles. The premium foams are produced exclusively in the EU and processed in Germany; even small quantities are manufactured precisely to customer specifications. In addition to distributing standard products, the company offers special clearance items from overproduction at irregular intervals.
- Site
- Pirmasens
- Processes
- Milling of foam (milling foams, CNC milling of orthopedic insoles), Production of EVA foams (in-house formulations, foam production), Conversion of foams (custom conversion, cutting), Production of EVA die-cut parts (sheets, wedges, compensation and supination wedges), Laminating of cover materials (LiteSteam laminated with 2 mm Flexolon), Gas sterilization suitable products (foams gas-sterilizable), Production of in-house formulations, Custom conversion
- Materials
- EVA foam (Litelon EX, 100% EVA), Hybrid EVA foam with rubber additive (Litelon KX), Bio-milling material from renewable raw materials (Biolon), EVA cushioning material (Flexolon), Latex with textile backing (Litelax, 3 mm), Microfiber cover material (LiteSteam), EVA build-up material (100% EVA, Antidust), EVA foam (100% EVA)
- Certificates
- DIN EN ISO 10993-5 (biological safety)
- Industries
- Orthopedic footwear technology, Medical technology
- 01
Development of in-house formulations
- 02
Foam production (EU)
- 03
Conversion/cutting (Germany)
- 04
Laminating
- 05
Distribution/delivery
Materials and Processes
EVA foam (100% EVA)
Milling foam in Shore A 15–70, specially developed for orthopedic footwear technology.
Hybrid EVA foam with rubber additive
Offers higher flexibility and improved resilience.
Bio-milling material from renewable raw materials
Environmentally friendly EVA alternative in Shore A 15–55 for orthopedic milling work.
Foot-shaped milling blanks
Monoblock and combination blanks with 2–3 Shore hardnesses, up to 40% less waste than conventional milling blocks.
EVA cushioning material
Lightweight cushioning material in Shore A 15–35 in various thicknesses and colors.
Latex with textile backing (3 mm)
Soft, pressure-relieving cushioning material specially for diabetic cushioning.
Microfiber cover material
Breathable, moisture-absorbing cover material, also available laminated with 2 mm Flexolon.
EVA build-up material (100% EVA)
Sheets, wedges (Keilschmiegen), compensation and supination wedges as well as die-cut parts in Shore A 35–65.
Location
Pirmasens
DEProduction, conversion and distribution
- Part weight / size
- Sheets approx. 90x50 or 100x60 cm; wedge 1050x350x30
- Lot size
- Small quantities to customer specification; clearance items from 10 cut pieces
- Materials
- EVA foams (Litelon, Biolon, Flexolon), latex (Litelax), microfiber (LiteSteam)
Components and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Milling of foam (milling foams, CNC milling of orthopedic insoles)Machining | – | – | – | – | EVA foam (Litelon), Bio EVA foam (Biolon), Hybrid EVA with rubber (Litelon KX) |
| Production of EVA foams (in-house formulations, foam production)Plastics | – | – | – | – | EVA foam |
| Conversion of foams (custom conversion, cutting)Plastics | – | – | – | – | EVA foam, Latex (Litelax), Microfiber (LiteSteam) |
| Production of EVA die-cut parts (sheets, wedges, compensation and supination wedges)Forming | – | 1050 mm × 350 mm × 30 mm | – | – | EVA foam (Litelon build-up material, |
| Laminating of cover materials (LiteSteam laminated with 2 mm Flexolon)Joining | – | – | – | – | Microfiber (LiteSteam), EVA foam (Flexolon) |
| Gas sterilization suitable products (foams gas-sterilizable)Surface | – | – | – | – | EVA foam (Litelon) |
Additional services
Quality and Biological Safety
The materials comply with DIN EN ISO 10993-5 for biological safety and are tested for skin compatibility, biological safety and cytotoxicity. Suitability for gas sterilization and resistance to most disinfectants are documented.
| Evidence | Pirmasens |
|---|---|
| DIN EN ISO 10993-5 (biological safety) |