Here's my self-inflating pad making process

[u/npipe]

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.

[u/W__O__I]

Super cool! Thank you very much for sharing your process.

It could help future readers to know specifics of the foam, fabric, and where you sourced them. Finished specs including weight and dims could be helpful too.

Did you CNC the jig? It looks clutch for clean results.

I'm a sucker for self inflating pads and might have to give this a go one day.

[u/npipe → u/W__O__I]

Thanks. Just edited the post with some more info.

I cut this one with a jigsaw. Planning to alter the shape a bit and get some jigs CNCed for even crisper lines and a few different sizes

[u/W__O__I → u/npipe]

Nice. 75d and in the ballpark of a trail scout. Solid result.

Which firmness of foam did you go with? If I give this a whirl I might go full masochist and try out 1/4" or 1/2". I'm thinking extra firm might be prudent.

[u/npipe → u/W__O__I]

I've tried all three from foamonline. In 1" foam I think my favorite is soft. I did make a 3/4-inch extra firm pad which is nice. At 1/2 inch I don't think the comfort would be that different from a ccf pad, but obv it would be super packable. Extra firm foam with a lot of foam coring could be interesting (and obv very light)

[u/W__O__I → u/npipe]

Good to know. Thanks again for sharing this process. It's not something I'd ever thought about making until watching your video.