Foam Replacement Program

Our crash pad shells are made from Global Recycled Standard (GRS)-certified recycled polyester with a TPU coating, built to withstand years of heavy use. In fact, the shells are so durable that they’ll likely outlast the foam inside. That’s why we’ve created the Foam Replacement Program.

This initiative reflects our commitment to reducing environmental impact by extending the life of quality gear and encouraging climbers to choose repair over replacement. 

Why replace foam?

Even the highest-quality foam gradually compresses and degrades over time. When that happens, shock absorption is reduced and uneven impact zones are created, making your landings less safe. 

Foam replacement isn't just about comfort, it's about protection. If your shell is still going strong, a simple foam refresh can restore your pad’s performance and keep you falling with confidence.

Reduce waste, not performance

Instead of sending an entire crash pad to landfill, the Foam Replacement Program allows you to reuse what’s still working - the shell - and replace only what’s worn out.

By doing so, we help to:

• Reduce unnecessary greenhouse gas emissions associated with manufacturing and transport
  
• Cut down on textile and foam waste
  
• Extend the lifespan of high-quality gear

How it works

We offer foam replacement for any Open Project crash pad at cost price (shipping at buyer’s expense), making it accessible to maintain performance—without the financial or environmental cost of a whole new pad.

1. Check for foam degradation

Signs your foam may need replacing:

What to Look For:

• Cracks, splits, or deep creases in high-impact zones
  
• Flattened or permanently compressed areas
  
• Yellowing, dustiness, or visible crumbling
  
• Uneven surfaces, warping, or sagging
  
• Foam flaking or breaking apart
  

What it Feels Like:

• Mushy or overly soft, lacking firmness
  
• Inconsistent density across the pad
  
• Slow or no rebound when pressed
  
• Noticeably less shock absorption during landings
  

2. Order a replacement foam kit

We’ll send you a full internal foam set, custom-cut to your pad’s dimensions using our original three-layer construction:

• Outer Layers: Continuous closed-cell foam for even impact distribution.
  
• Middle Layer: Open-cell foam for soft catch and ground protection.
  

Shipping is calculated at checkout.

3. Refresh and reassemble

No tools required - just open the velcro, swap out the foam, and your pad is ready to go.

This program is designed to support both your safety and the planet. Keep climbing, keep committing, and when the time comes, refresh, don’t replace.