Foam Fabricating Companies

Foam fabricating is the manufacturing of a lightweight, versatile, polymer-based material. The material, such as plastic or polyurethane, is frothed up while in a molten state and then cooled, which fills the material with countless little bubbles, giving it an appearance similar to a sponge.

Foam fabricating is a broad term used to describe types of foam, applications and uses of those types and the products that can be formed from foam materials. Foam is simply a substance formed that consists of a number of air bubbles trapped in a liquid or a solid. Foam fabricators classify their product by two categories: open-cell foam and closed-cell foam. Closed-cell foam contains foam cells which are sealed, or “closed” and separate from one another. This foam is very dense and has high compressive strength. Because the cells are not broken in this foam and gas and liquid molecules do not freely travel from cell to cell, the cells expand when exposed to heated gas. The expansion fills the material, making closed cell foam an excellent heat insulator, like spray foam. Open-cell foams are lightweight, spongy, soft foams in which the cell walls or surfaces of the bubbles are broken and air fills all of the spaces in the material. This makes the foam soft and weak; as a result, open-cell foams are commonly used for foam padding and foam cushions. In addition, open cell foams are effective as sound barriers, having about twice the sound resistance as closed cell foam. The medical, construction, automotive, electronics and furniture industries all use foam products.

Some Leading Manufacturers

American Foam Products

Painesville, OH | 440-352-3434

Our foam products offer a number of benefits such as high impact resistance. These solutions are ideal for a plethora of applications and our high performance foam will last you for many years to come. These cost efficient foam products can be customized to your requirements and we extensively test all of our solutions. Turn to American Foam Products today for high quality foam!

Rempac Foam Corporation

Rochelle Park, NJ | 800-394-7885

Turn to Rempac Foam Corporation for reliable open and closed cell foamed plastic and sponge rubber materials. Our abrasive coated sponges are an ideal choice for many applications and our cleaning sponges are utilized in consumer, commercial and institutional markets. We are dedicated to customers and we strive to manufacturer the best products possible. If you have any questions then please give one of our representatives a call!

Williams Foam

Sylmar, CA | 800-709-3626

For high quality foam solutions, Williams Foam has the products and services you need! We specialize in the design, development, and fabrication of custom polyurethane, polystyrene, and polyethylene foams. For more than 30 years, companies from the packaging, aerospace, manufacturing, automotive, and architectural industries have trusted us for their foam fabrication solutions. Contact us today with your foam requirements!

Heubach Corporation

Garland, TX | 800-530-0091

Heubach Corporation is a leader in the conversion and manufacture of flexible materials. We offer a wide variety of foam fabricating solutions, and over our more than 20 years of operation, we have developed many innovative, reliable, and high quality foams and foam products. We use only the highest quality materials, and we provide our customers with the most cost effective solutions on the market. Please visit our website for more information or give us a call today!

Thrust Industries

Evansville, IN | 800-467-6730

As a world-class, ISO 9001:2008 certified company, Thrust Industries is committed to designing and manufacturing quality foam products. We are the trusted source for foam fabrication solutions for many customers in the electronics, telecommunication, appliance, automotive, and computer industries. We offer a diverse range of fabrication services, including die cutting and laser cutting. Give us a call for more information!

Design Converting, Inc.

Grand Rapids, MI | 616-942-7780

Design Converting is a foam fabricating expert. With a diverse range of manufacturing capabilities, we can create all kinds of customized foam products for your specific and unique applications. We offer exceptional engineering services along with material analysis and assembly services. Our goal is to find the most cost effective solution for you, and we will work closely with you to guarantee your satisfaction! For your quality foam fabrication solutions, call Design Converting today!

Foam fabricating services, such as foam cutting, work with many types of foam for numerous applications. The most common foam used is polyurethane foam, which is resilient closed-cell foam that biodegrades in direct and indirect sunlight. Typical applications for urethane foam include surgical scrubbers, x-ray positioning pads, EKG pads, insulation foam, protective foam padding, flexible foam seating and custom insulated containers. Polyethylene foam is a closed-cell, expanded, extruded, flexible plastic foam with predictable shock absorbing qualities. Used mainly as a protective packaging material, polyethylene foam is used to wrap products such as computer components, frozen foods, furniture, signs, sporting goods and clothing. Ethafoam is polyethylene foam that offers excellent shock absorption qualities and is often used for blocking, cushioning and bracing protection in material handling and shipping. Polyether foam is low-cost polyurethane foam that provides good cushioning and has acoustic and packaging properties. PVC foam is closed-cell vinyl foam that is pliable and soft and used in gaskets to prevent water transmission. Expanded polystyrene (EPS) is being used in some surprising applications: as padding foam in bedroom slippers, filter foam in air conditioning units, insulation foam, oil rigs, weather balloons and satellites.

Foam can be made from a variety of materials including plastic, low density elastomers and rubber. Typically formed from polymers, foam is made by mixing a number of chemicals and adding a gassing agent. The addition of the gassing agent causes the material to expand and form a foam strip. The foam is comprised of numerous gas bubbles trapped in the material. After foam is formed, a variety of foam fabricating services can be performed, including several types of foam cutting processes. Die cutting is a common foam fabricating process, in which different shapes are cut out of foam strips, blocks or sheets. Water jet cutting uses a fine stream of water under ultra high pressure to perform the same function as die cutting, but offers extremely close tolerances that die cutting cannot achieve. Hot wire cutting utilizes a heated wire in order to form smooth, straight cuts in the foam. There are also several types of foam forming processes. A popular foam forming process is thermal-forming, in which bulk foam materials are heated in order to produce machining shapes like foam sheets. Another forming process, foam felting, produces denser foam materials by means of compressing and curing thick, soft foam materials.

Foam fabricating services produce a large amount of scrap. The first major source of scrap is produced during foam production as well as foam die cutting processes. Foam scrap is produced as a result of the startup and shutdown of the production line when manufacturing runs are changes over and when foam blocks are cut and shaped into the desired end product. The second major source of foam scrap is foam products that have reached the end of their useful life. Scrap foam is often shredded and rebonded and then used for such products as carpet padding and filler for pillows and furniture. Foam scrap can also be burnt in order to reduce waste bulk; however this was more popular in past decades. Although the burning of foam is considered to be non-toxic by U.S. government agencies, as a result of growing environmental concerns and more stringent carbon dioxide emission regulations, many foam manufacturers have turned to recycling as a waste handling method. Recycling offers manufacturers the ability to recoup return on investment, which would be lost by burning the scrap. Although the use of recyclable foam materials is growing, the process of collecting the foam, separating out the contaminants and then shipping the foam economically can be time consuming and costly to those foam manufacturers wanting to recycle.

American Excelsior Company

American Excelsior CompanyFoam Fabricating – American Excelsior Company