Abstract: The present invention includes a foam flame bonded fabric laminate that is wind-resistant, breathable, and supple along with a low cost process for producing it. The apparatus of the present invention comprises a foam bonding agent layered between fabrics or other materials where the foam possesses wind-resistant and breathable characteristics independent of the other layers. The process of the present invention involves two-step foam flame bonding with each step accomplished in a separate pass through a laminating device. In one embodiment, the first step includes lightly exposing a thin polymer foam (such as polyester polyurethane or polyether polyurethane) to a flame without preheating, then pressing it against the inner face of mesh or tricot. The second step includes more vigorously exposing the foam face of the foam-mesh or foam-tricot laminate to a flame, then pressing it against the inner face of a berber, pile, or fleece fabric.