Felt Baffles vs Foam Baffles: Acoustic Performance Compared

The Materials

Felt baffles are made from compressed PET (polyethylene terephthalate) felt — essentially recycled plastic bottles processed into a dense, fibrous panel. Available in thicknesses from 9mm to 24mm. The material is self-finished — no wrapping or covering needed. PET felt comes in dozens of colors and can be CNC-cut into custom shapes.

Foam baffles use open-cell melamine foam or polyurethane foam. Melamine foam (the type used in commercial acoustics) is lightweight, has excellent high-frequency absorption, and is inherently fire-resistant. Polyurethane foam is cheaper but has serious fire safety limitations that disqualify it from most commercial installations.

Acoustic Performance

This is where the differences matter most:

NRC Ratings

Felt baffles (12mm): NRC 0.45-0.55
Felt baffles (24mm): NRC 0.60-0.80
Melamine foam baffles (2"): NRC 0.85-1.00
Melamine foam baffles (3"): NRC 0.95-1.10

Foam wins the raw numbers contest. Melamine foam absorbs more sound per unit than felt because its open-cell structure is more acoustically transparent — sound energy enters the material and dissipates through friction within the cell structure.

Felt is denser and reflects more mid-to-low frequency sound at the surface before it can enter the material. This makes felt less absorptive per inch of thickness but still effective, especially in thicker profiles.

Frequency Response

Foam baffles absorb effectively across a wider frequency range, including lower frequencies down to 250 Hz. Felt baffles perform best at mid and high frequencies (500 Hz and above) and lose effectiveness at low frequencies unless they're thick (24mm+).

In practical terms: if your noise problem is primarily speech (500-4000 Hz), both materials work. If you need to control lower-frequency noise from HVAC, machinery, or music, foam baffles have an advantage.

Fire Safety

This is the most important consideration for commercial installations and where foam carries risk.

PET felt: Most commercial PET felt panels achieve Class A fire rating (flame spread ≤ 25, smoke developed ≤ 450 per ASTM E84). PET is inherently slow to ignite, self-extinguishing, and produces relatively low smoke. It's accepted in virtually all commercial occupancies including assembly spaces.

Melamine foam: Class A fire rated. Melamine foam is inherently fire-resistant — it chars rather than melting and produces low smoke. This is the foam type that's acceptable for commercial use.

Polyurethane foam: This is the problem material. Standard polyurethane foam is highly flammable, produces toxic smoke, and cannot meet Class A requirements without extensive fire-retardant treatment. Even treated polyurethane is viewed skeptically by fire marshals. We do not install untreated polyurethane foam in commercial buildings. Period.

If someone quotes you "foam baffles" at a price that seems too good, ask what type of foam. Polyurethane is cheap but dangerous. Melamine is the safe commercial option.

Aesthetics

Felt wins here. PET felt baffles look polished and intentional. The material has a natural textile quality, comes in 40+ colors, and can be laser-cut or CNC-cut into custom shapes — curves, geometric patterns, brand logos. Designers love felt baffles because they're a design element, not just an acoustic treatment.

Melamine foam baffles are typically white or light gray and have a porous, industrial appearance. They look utilitarian. Some manufacturers offer fabric-wrapped foam baffles to improve appearance, which closes the aesthetics gap but adds cost.

For spaces where design matters — hotel lobbies, corporate offices, retail spaces — felt baffles are the clear choice. For spaces where appearance is secondary — school gymnasiums, warehouses, mechanical rooms — foam or fiberglass baffles make more sense.

Durability

Felt: Extremely durable. PET felt resists moisture, won't sag in high humidity, doesn't harbor mold or bacteria, and maintains its shape indefinitely. It can be vacuum cleaned. Color is throughout the material so scratches and cuts don't reveal a different color underneath.

Melamine foam: More fragile. Melamine foam is brittle and can chip or crumble on impact. It's not suitable for environments where physical contact is possible (gyms, recreation areas). It also absorbs moisture and can degrade in high-humidity environments.

Weight and Installation

Both materials are lightweight, but foam is lighter. Melamine foam weighs approximately 0.5 lb/SF for 2" panels; felt runs 0.8-1.5 lb/SF depending on thickness. Neither material requires heavy-duty suspension systems.

Installation methods are similar: both hang from aircraft cable or wire with simple attachment hardware. Felt baffles often have reinforced top edges or built-in hanging channels. Foam baffles may need adhesive-mounted clips or through-bolt attachments.

Environmental Impact

PET felt scores well here — it's made from up to 60% recycled content (post-consumer plastic bottles) and is itself recyclable. It contributes to LEED recycled content credits.

Melamine foam is petroleum-based and not recyclable through standard channels. Its environmental profile is less favorable, though its durability and long lifespan partially offset the manufacturing impact.

Cost Comparison

PET felt baffles: $12-$22 per square foot of baffle, installed
Melamine foam baffles: $8-$16/SF, installed
Fabric-wrapped foam baffles: $14-$24/SF, installed

Foam is cheaper for raw acoustic performance. Felt costs more but delivers better aesthetics and durability.

Our Recommendation

Choose felt baffles when the space is visible to clients, customers, or visitors, when design matters, and when the budget supports the premium. Choose melamine foam baffles when pure acoustic performance per dollar is the priority and appearance is secondary.

Never use polyurethane foam in commercial spaces. And if you're comparing baffles to other acoustic treatments, read our baffles vs clouds comparison and baffles vs ceiling tiles breakdown.