I always thought it would be great to have a pad with two separate densities, for a few reasons. There are some obvious technical limitations, however.
Basically, when working on fairly flat surfaces, there is uniform pressure on the pad, but not uniform speed. This causes different parts of the pad to work at different rates. If there were non-uniform densities in the pad, I believe that it would potentially even these differences out with some benefits. I think a cross-section would look something like this:

(the crudeness of this drawing from MS paint is laughable, considering my engineering CAD background)
This way, as downward pressure is applied, the middle, slowest-spinning area receives increased pressure for increased working power. The middle, medium-density foam will be more compressed.
There could be other advantages as well. If the upper, higher density portion could be designed to be less absorbent (perhaps made out of something like TPU?), it would reduce the rate at which the pad loads up, as product would be forced more outwardly than upwardly. When the product gets to the velcro, the pad's basically useless.
Additionally, there would be more give when working in non-flat areas. Since the edges of the pad are softer than the flat center, there would be more forgiveness in them. This would probably be a negative for those needing hyper-consistency, or would at least take some getting used to. Or, perhaps, they could be designed to be firmer, giving the ability to work in tighter spots with more flexibility.
The very soft portion is somewhat of an afterthought. It certainly wouldn't work on a rotary, as it would probably spin off, but perhaps on a G100 it would be feasable. The basic idea is to make the pad be able to kiss a surface it hits laterally without marring it.
Revision: This is kind of more what I was thinking of, but I put the first one in because it has my labels in it...

Now, the final and probably biggest challenge would be to effectively and permanently bond the foam together in a way that it would not separate, under speed, vibration, product moisture, etc. That's probably what would kill this idea. Just thinking out loud, anyway....
Basically, when working on fairly flat surfaces, there is uniform pressure on the pad, but not uniform speed. This causes different parts of the pad to work at different rates. If there were non-uniform densities in the pad, I believe that it would potentially even these differences out with some benefits. I think a cross-section would look something like this:
(the crudeness of this drawing from MS paint is laughable, considering my engineering CAD background)
This way, as downward pressure is applied, the middle, slowest-spinning area receives increased pressure for increased working power. The middle, medium-density foam will be more compressed.
There could be other advantages as well. If the upper, higher density portion could be designed to be less absorbent (perhaps made out of something like TPU?), it would reduce the rate at which the pad loads up, as product would be forced more outwardly than upwardly. When the product gets to the velcro, the pad's basically useless.
Additionally, there would be more give when working in non-flat areas. Since the edges of the pad are softer than the flat center, there would be more forgiveness in them. This would probably be a negative for those needing hyper-consistency, or would at least take some getting used to. Or, perhaps, they could be designed to be firmer, giving the ability to work in tighter spots with more flexibility.
The very soft portion is somewhat of an afterthought. It certainly wouldn't work on a rotary, as it would probably spin off, but perhaps on a G100 it would be feasable. The basic idea is to make the pad be able to kiss a surface it hits laterally without marring it.
Revision: This is kind of more what I was thinking of, but I put the first one in because it has my labels in it...
Now, the final and probably biggest challenge would be to effectively and permanently bond the foam together in a way that it would not separate, under speed, vibration, product moisture, etc. That's probably what would kill this idea. Just thinking out loud, anyway....
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