Nugget’s BFF: Best Foam Forever

Sometimes the most simple pairings are the most iconic. Peanut butter and jelly? Hard to beat. Milk and cookies? C’mon. At Nugget, we have a few favorite combos: toy and furniture, style and function, and of course, foam and fabric.

We wrote up a love poem to our fabrics recently, and we would be remiss if we didn’t share our equal enthusiasm for our foam! Read on for all the information you need to win that next round of trivia night that focuses all on the original play couch. 

Making a Splash from the Start

When Nugget first started, our prototypes used a very different sort of foam than we use now, one that you’d be more likely to find floating in a pool than jumping around in a playroom. That’s right! We used pool noodle foam, which proved to be great for holding a static form, but not so great for endless play possibilities. 

After reviewing options on the market, we found an open cell foam option that was more comfortable and malleable, but still sturdy enough to withstand countless jumps, builds, and obstacles courses. We’re proud to work with a foam manufacturer based right here in our home state of North Carolina to offer OEKO-TEX Standard 100 certified products. Our foam is cut to different shapes and sizes out of a huge block of foam called a bun (really!) and then sent over to Nugget HQ for assembly.

Cartoon comparing a hamburger bun and foam bun

When you order a Nugget, you receive six pieces of foam: two for the base, two for the cushion, and two pillows, all covered in our microsuede fabric. The cushion foam is thinner and more flexible for easy movement and comfortable lounging, while the base foam is cut thicker and sturdier to provide a stable foundation. In other words, they really put the “fun” in “function!Not only do you receive multiple pieces of foam, but each is slightly different and unique to the functionality of each piece. Pillows are medium density and medium firmness to provide soft support (the Goldilocks of the Nugget), while thin cushions are high density and low firmness for flexible play. The bases are made with low density foam and high firmness (the opposite of cushions) to provide a more solid structure that’s perfect for builds. These choices were made intentionally, both for individual shapes’ function, as well as the way they interact together. That wonderful mix of squish and structure that a Nugget couch provides — that’s no accident!

All A-Bounce Foam

There are a number of different types of foam (who knew?!). We selected our foam because it functions more like a spring — able to return to shape and form after compression, and quite breathable. In fact, mattress companies often use open cell foam as well, for some of the same reasons we do, including its ability to spring back to form after compression. 

Hand holding up one triangle of foam on a gray background

However, unlike mattresses, which tend to come with their foam fully covered, Nugget foam is easily visible and accessible after removing your microsuede cover set. For those of us who are interested in the nitty gritty of how it’s made, this means that you might see some things that you’ve never noticed before with other foam products.

Since foam is made by incorporating an inflating agent into a raw material, sometimes, bubbles form throughout the foam and show on the surface once the foam is cut. Not to worry, though! Bubbles and slight imperfections are a completely normal part of the foam-making process and don’t affect the look or use of the product in any way. Additionally, all foam, including ours, can oxidize over time, which can slightly alter the color of the foam, but again, not the function. 

Shipment incoming! Using our <a href="https://nuggetcomfort.com/blogs/big/big-machines-of-hq-the-beluga">Beluga machine</a>, we compress the foam with the weight of an African forest elephant, roll the Nugget into a burrito, and ship it to your house. After such a voyage, don’t be surprised if your Nugget is wrinkly upon delivery — just like the elephants we used to prep it — but it will smooth out within a day or so. Playing and jumping on the Nugget actually helps it spring back to form faster, so play on, Nuggeteers!

Foam Care 101

We get it, accidents happen. Our recommendations are simple: when foam is affected by any liquids or substances, use a damp rag and some gentle soap or your favorite upholstery cleaner, spot clean, and then let it fully dry before getting it dressed for play. Because the foam is covered up with fabrics during use, it is very important to let it dry completely after any kind of cleaning treatment. 

Steps to care for foam: 1) Use a damp cloth 2) Add gentle soap or upholstery cleaner 3) Spot clean and 4) Let it fully air dry.

Is your Nugget looking a little wonky? Sometimes foam can get a bit squished around in the fabric (especially in the corners and along the edges), either because of play, or the static of microsuede getting stuck to the foam in the wrong spot. If this happens, it’s time for a reset! Simply unzip your Cover Set, refloof (it’s a word, right?) the foam, let it breathe outside the fabric for up to 24 hours, and then zip the covers back up, and voila! All done.

At Nugget HQ, we’re constantly working to bring Nuggeteers the best product possible. We integrate quality assurance in every step of the process, from foam and fabric inspections to Big Orange Box delivery. You can rest easy on our comfy foam, knowing that we’ve got your back (and it does too).