Independent foam cell surface and method of making same

A method of making independent foam cell surfaces, the method comprising the steps of:

• a) selecting at least three resilient members, the at least three resilient members including two sacrificial sheets and a foam blank;
• b) forming a pre-extraction blank by stacking the at least three resilient members on top of each other such that the foam blank is positioned between the two sacrificial sheets;
• c) providing two cylindrical rollers, each of the rollers defining a plurality of roller peaks extending radially therefrom, the roller peaks being disposed in spaced-apart relation such that a plurality of roller valleys are formed therebetween, each of the roller peaks being arranged in generally equidistant relation so as to form a pattern;
• d) positioning the two cylindrical rollers adjacent each other such that rotation of the rollers in opposing directions aligns the roller peaks on one of the rollers to insert into the roller valley of another one of the rollers;
• e) feeding the pre-extraction blank in-between the rollers such that the rollers apply force upon the first and second sacrificial sheets to depress portions of the foam blank thereof;
• f) providing a cutting edge disposed adjacent the rollers;
• g) applying the cutting edge to the pre-extraction blank as the pre-extraction blank passes through the rollers;
• and
• f) removing the two sacrificial blanks from the pre-extraction blank.