That's basically it - a cheap bulk foam filler. Thanx
How cheap is cheap? Self-expanding foam can already be purchased at your local hardware store in the US, and to the best of my knowledge, it isn't the sort of thing that bugs want to eat. Not sure about other countries, but definitely here in the US. Cost is under $10 per canister.
Self-expanding foam works by mixing two or more chemicals together, in which one decomposes during the reaction into a gas, forming bubbles, and the other(s) form the cell walls.
FYI, One tricky thing about using these products is that they have a great deal of quasi-hydraulic strength. Apply too heavily in a closed space like behind a Drywall construction can result in damage of the drywall.
I believe the same could be said for plaster-lathe. The foam has an incredible ability to deform a wall.
As for literally "making" it yourself, (adding purchasable chemicals together), I'm honestly not sure how that can be done by an average citizen. I suspect that it might be difficult to obtain the consituent chemicals without some sort of contractors license or similar. Generally speaking, we are expected to buy cans of foam or hire a contractor to install it.
Hmm...I also know that the packaging industry sells something to companies for shipping&receiving; departments, although aside from that clue I can't point you directly because my knowledge stops at "knowing that shipping and receiving departments can get it"
best of luck
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Dow Corning sell "Froth-Pak" a two component foam system for insulation and goods shipping.
The ingredients in self-hardening foams are closely guarded trade secrets. Even if you had such a recipe, building the exotic molecules would be a complex process involving dangerous chemicals, probably generating hazardous waste in the process. You're prettymuch forced to buy the stuff from a chemical company. Check out Instafoam or the cans of expandable foam they sell at the hardware store, ex. Great Stuff®
Okay...you peaked my interest...here's a link to a company that sells a bit more than little cans...they ain't cheap though!http://www.energyefficientsolutions.com/sprayfoam.asp