Most of the polyurethane foam insulation shapes we create are cut from blocks we make with our foam-pouring equipment which mixes chemicals to precise ratios.
Sometimes we cannot cut a shape as one piece because of its three-dimensional configuration, if it is larger than the largest block we can make, or if it would be very wasteful of material. In these cases, we will break down the shape into smaller components and then glue them together. If the resultant shape is too large to ship, we will ship it in parts for our customers to assemble during installation.
This method of fabrication does not affect its insulation value.