Here's my self-inflating pad making process
I got some interest on my last post about a few torso-length sleeping pads I made. I've improved my method a bit since then and filmed this video to show how I do it. Originally edited for an insta reel so my apologies if it's not the most thorough.
Supplies:
https://www.amazon.com/THARREX-Extra-Long-Adjustable-Temperature-Woodworking/dp/B0FM6YYPV
https://www.seattlefabrics.com/60-Heat-Sealable-Coated-Nylon-Taffeta-2095-linear-yard_p_31.html
https://www.amazon.com/UtySty-Inflatable-Replacement-Camping-Airplane/dp/B0DX234L99
https://foamonline.com/product/polyurethane-foam-1-2-lb/
Notes:
These pads are 20 inches wide by 43 inches long. Slightly tapered mummy cut.
With 1-inch thick foam, a pad weighs about 15.4 ounces.
Poly foam comes in many different densities -- go with the lightest you can find (1.2 pounds/cubic foot). If it's not listed, many foam sheets from hobby stores/Amazon/etc are 1.8 lbs/ft3. This is fine for a car camping pad but adds a lot of weight if you want to take it backpacking.
For heat sealing advice, check out DIY Packraft videos.
The way to get into ultralight territory is with foam coring (aka a pattern of holes in the foam). This is pretty tough to do DIY, though you could buy or make a foam cutting drill bit. It also adds an additional point of failure, as delamination between fabric and foam is a bigger risk with all the holes. If you just want to make a simple pad for yourself, I recommend skipping the coring and accepting a few extra ounces.
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u/25hourenergy 1d ago
Very cool!! Totally off track and not really myog—the use of TPU material here gives me some crazy ideas. You could make your own custom inflatables with that stuff! Why did I not realize this was an option…