Precision Pad Engineering: Inside the Development Process
Sourcing and Initial Material Selection
At Matt’s Magic Detail Tech, innovation begins at the cellular level. We start by sourcing samples of high-performance foams directly from our specialist foam chemical partners who also manufacture and convert foams.
From foam blocks like those you can see here as well as two by one metre sheets and even A4 sheets of foam samples, each foam is carefully selected based on their technical specifications – there is a minimum range that they must exceed in order to be selected and when they arrive, they are precisely CNC-machined into our three different generations of pad designs in 90 mm, 140 mm and 150 mm before we reshape the edges of the foam into whatever profiles we like ready for our rigorous evaluation.
In parallel, we engage with material innovators worldwide to explore next-gen materials with the potential to transform the pad industry—introducing both evolutionary enhancements and breakthrough revolutions in pad material, design and performance.
Advanced Interface Development and Testing
To optimise power transfer from polisher to paint, retain or enhance pad contourability on various panel shapes of vehicles and improve pad longevity, we test a wide array of interface materials.
Using CNC technology, we cut to shape these materials which are specialised high temperature resistance materials with each one having several hardness grades to choose from. We laminate each material type and grade to the polyurethane foams we’ve chosen to sell and then test the prototype pads to determine which material and grade makes the best interface layer for each particular foam. Once prototype pad testing is done and the best combinations are found, the pads go into production.
Every prototype undergoes in-depth R&D across all polishing machine types, with particular emphasis on rotary and large-orbit dual-action units.
Our mission: identify the ideal interface and foam pairings that deliver maximum performance, stability and durability plus enhanced user feel and the elimination of pad wobble with ultra soft foams on DA polishers due to our advanced pad designs
Investment in Premium Materials and Rigorous Quality Control
Investment in these advanced materials can range into the thousands, with some premium interfaces costing up to $200-$300 per sheet.
And with development times often exceeding 50-100 hours per pad, only the most durable and high-performance foams and interface materials make the cut.
We reject any polyurethane foams prone to rapid softening from a lack of density, structural disintegration (crumbling during use) or those which offer nothing new beyond what’s already on the market. We’re interested in breaking new ground not copying.
Any interface materials that negatively effect a pad’s ability to conform to panel shapes and give a smooth buffing feel are not used.
Thanks to this obsessive testing regime and direct feedback from elite detailers across Australia, we’ve launched our Super Series range which is refined, balanced and engineered for pro’s and enthusiasts
Next-Generation Innovation and Local Manufacturing
We are excited to soon begin trialling polishing pad production right here in Adelaide as we then have more control over quality and as the business grows and sales increase, purchasing sheets in bulk or blocks becomes a more viable option and should keep pads affordable for our customers.
Currently manufactured by our carefully selected European and Japanese factories, one of our goals is to switch from overseas manufacturing to small then medium and eventually large-scale pad production as well as innovation to supply to the detailing, crash repair, restoration and marine care industries.