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For bra padding and lingerie support materials, thickness is not the only specification that matters. FOAM density, softness, rebound, and support can also affect cutting, shaping, processing, and the final performance of the finished product. In thi...
For bra padding and lingerie support materials, thickness is not the only specification that matters.
FOAM density, softness, rebound, and support can also affect cutting, shaping, processing, and the final performance of the finished product.
In this project, our customer Alice from Ghana contacted us looking for a white laminated material suitable for bra padding and lingerie support components.
Alice already knew that she needed 5mm and 13mm thicknesses, but she was not sure which FOAM density would be more suitable for her application.
As a direct manufacturer specializing in laminated fabrics and raw composite materials, we evaluated her application requirements and used our production experience to recommend the following structure:
White Knitted Fabric + Approximately 23D PU FOAM + White Knitted Fabric
The material was produced in both 5mm and 13mm thicknesses.
Alice needed the material mainly for bra padding, lingerie inserts, support components, and other soft shaping applications.
She wanted white knitted fabric on both sides with PU FOAM laminated in the middle.
Because her products had different structural requirements, she needed two thickness options:
5mm and 13mm.
However, one important question remained:
What FOAM density should be used?
Different FOAM densities can create different hand feels and structural performance, even when the thickness is the same.
If the FOAM is too light and soft, it may not provide enough structure or support. If it is too firm, it may affect the softness and shaping performance required for lingerie applications.
Instead of asking Alice to simply choose a density herself, we discussed her final application, desired hand feel, and processing requirements in more detail.
The key question was not whether 5mm and 13mm were available.
The real question was:
Which FOAM density would work better with these thicknesses and her final products?
After further communication, we confirmed that the material needed to provide:
Based on our experience in producing knitted fabric laminated with PU FOAM, we recommended:
Approximately 23D PU FOAM
This density provides a suitable balance between softness, cushioning, and structural support for this type of bra padding and lingerie application.
For this reason, both the 5mm and 13mm specifications use approximately 23D PU FOAM.
This is also an important part of the value we provide as a direct manufacturer:
Customers do not always need to know every technical specification at the beginning. We can help determine a more suitable material solution based on the final application.
After the FOAM density was confirmed, we finalized the two thickness options.
The 5mm material is relatively lightweight and easier to cut, sew, and shape, making it suitable for products requiring a thinner structure.
The 13mm material provides more thickness and cushioning space, making it suitable for products requiring a fuller or more three-dimensional structure.
Both specifications use the same material structure:
White Knitted Fabric + Approximately 23D PU FOAM + White Knitted Fabric
The main difference is the thickness of the middle FOAM layer.
Once the material structure, FOAM density, and two thicknesses were confirmed, we arranged bulk production.
As a direct laminated fabric manufacturer, the main production stages — from raw material preparation and PU FOAM specification confirmation to double-sided lamination, rolling, and finished material preparation — are completed in our factory.
The white knitted fabric covers both sides of the PU FOAM, creating a soft and even surface while making the material suitable for subsequent cutting, sewing, and shaping.
White knitted fabric and PU FOAM during the lamination process.
After production was completed, the 5mm and 13mm materials were rolled, organized, and packaged separately.
The two specifications were clearly separated during production and packaging to make identification, storage, and use easier for the customer.
After packaging, the goods moved to the next stage of transportation according to the customer's logistics arrangement.
Customer Inquiry
Material required for bra padding and lingerie support
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Application Confirmation
5mm and 13mm thicknesses required
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Key Question Identified
The customer was unsure which FOAM density to choose
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Further Communication
Softness, cushioning, support, and processing requirements confirmed
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Professional Recommendation
Approximately 23D PU FOAM recommended based on application and production experience
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Final Material Structure
White Knitted Fabric + Approximately 23D PU FOAM + White Knitted Fabric
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Factory Production
5mm and 13mm specifications produced separately
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Rolling & Packaging
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Loading & Delivery
Alice already knew her final application and the two thicknesses she needed, but she was not sure which FOAM density would be more suitable.
As a direct laminated fabric manufacturer, we used our production experience and understanding of the application to help her select approximately 23D PU FOAM and finalize the complete material structure.
For us, laminated fabric manufacturing is not simply about bonding fabric and FOAM together.
It is about first understanding the customer's final product, and then using our material and manufacturing experience to help develop a more suitable solution.
Shanghai Dongyao Shoes Material Co., Ltd., established in 2002 near Shanghai Port, is a leading laminated fabric manufacturer. We specialize in high-quality composite fabrics serving medical, automotive, sports protection, and luggage industries with reliable export logistics and innovation.
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