Apparatus for automated manufacture of welded foam structures

An apparatus for manufacture of foam structures, comprising:

• a platform for supporting at least two foam components to be welded together;
• a foam component positioning mechanism for positioning a first foam component relative to a second component, and
• a foam welding head mounted to travel along an interface between the first and second foam components and operative to weld the first and second foam components together and a foam cutter operative to cut a portion of the first or second foam component proximate to a weld between the first and second foam components, wherein the foam cutter is located on the foam welding head further comprising a gripping mechanism for gripping an internal component for combination with the first or second foam components.

An apparatus for manufacture of foam structures comprising:

• a platform for supporting a first foam component and a second foam component in contact with the first foam component at an interface;
• a clamp for maintaining the second foam component in a position relative to the first foam component;
• and a welding head operative to weld the first foam component to the second foam component at the interface, the welding head having an interface blade and a nozzle configured to pass through the interface, and a trimmer operative to trim one of the foam components, wherein the trimmer is mounted on the welding head.

An apparatus for forming a weld between two separate foam components, the apparatus comprising:

• a platform for supporting first and second foam components;
• a rail proximate to the platform and located for positioning at least one of the foam components proximate to the rail;
• a welding head mounted to translate upon a track generally aligned with the rail, the welding head having an interface blade positioned to travel between an interface of the two foam components, and a nozzle adapted to distribute a heated gas at the interface of the two foam components, and the second rail, a second track and a second welding head associated with the platform.