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A method for manufacturing a cushioning element may include securing a plurality of pad components to pins that extend outward from a base, each of the pins having a non-circular short-axis cross-sectional shape. The pad components are then compressed between the base and a material layer to bond th

A method for manufacturing a cushioning element may include securing a plurality of pad components to pins that extend outward from a base, each of the pins having a non-circular short-axis cross-sectional shape. The pad components are then compressed between the base and a material layer to bond the pad components to the material layer. In some configurations, the pins may have an elongate short-axis cross-sectional shape. In some configurations, the pins may have an elliptical short-axis cross-sectional shape. Additionally, in some configurations, the pins may have a short-axis cross-sectional shape selected from triangular, square, rectangular, hexagonal, and semi-circular.

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1. A method of manufacturing a cushioning element, the method comprising: providing a die and an extractor, the die having a plurality of die elements and the extractor including a plurality of pins with a non-circular short-axis cross-sectional shape;locating a polymer foam material between the die

1. A method of manufacturing a cushioning element, the method comprising: providing a die and an extractor, the die having a plurality of die elements and the extractor including a plurality of pins with a non-circular short-axis cross-sectional shape;locating a polymer foam material between the die and the extractor;compressing the polymer foam material between the die and the extractor, the die elements cutting the polymer material to form a plurality of pad components, and the pins extending into the pad components;separating the die and the extractor, the pad components being secured to the pins; andbonding the pad components to (a) a first material layer with the extractor and (b) a second material layer. 2. The method recited in claim 1, wherein the step of providing the die and the extractor further includes positioning the die elements and the pins in offset rows. 3. The method recited in claim 1, wherein the step of providing the die and the extractor further includes shaping the pins to have an elongate short-axis cross-sectional shape. 4. The method recited in claim 1, wherein the step of providing the die and the extractor further includes shaping the pins to have a short-axis cross-sectional shape with rounded sides and pointed end areas. 5. The method recited in claim 1, wherein the step of providing the die and the extractor further includes shaping the pins to have a short-axis cross-sectional shape selected from a group consisting of triangular, square, rectangular, hexagonal, and semi-circular. 6. The method recited in claim 1, wherein the step of bonding includes forming a thermalbond between the pad components and the first material layer. 7. A method of manufacturing a cushioning element, the method comprising: cutting a polymer foam material to simultaneously form a plurality of pad components arranged in rows;securing the pad components to pins of an extractor, the pad components being arranged in the rows, and the pins having a non-circular short-axis cross-sectional shape; andbonding the pad components to at least one material layer with the extractor; wherein the step of securing includes piercing the pad components with aplurality of pins from the extractor. 8. The method recited in claim 7, wherein the step of cutting includes utilizing a die with a plurality of die elements arranged in rows. 9. The method recited in claim 8, wherein the step of cutting further includes compressing the polymer foam material between the extractor and the die elements. 10. The method recited in claim 7, wherein the step of securing further includes arranging the pins in rows. 11. The method recited in claim 7 wherein the step of bonding includes forming a thermalbond between the pad components and the material layer. 12. The method recited in claim 7, further including a step of selecting the pins to have a short-axis cross-sectional shape selected from a group consisting of triangular, square, rectangular, hexagonal, and semi-circular.