Foam Fabricating Companies

Foam fabricating is the process of manufacturing a material that is versatile, lightweight, and polymer-based. The material is melted down, frothed up, and cooled, filling the material with little bubbles and giving it a sponge-like appearance. A couple of examples of materials used to make foam are polyurethane and plastic. Foam is used across a wide range of industries such as furniture, electronics, automotive, construction, and medical.

The term “foam fabricating” can be used to describe the types of foam and the various uses and products that can be made from them. Foam is defined as a substance that consists of countless little air bubbles trapped in a solid or liquid state. Foam fabricated products can fall under two categories: closed-cell or open-cell foam. The first category, closed-cell foam, contain foam cells which are sealed and separate from one another, or “closed.” Closed-cell foam has a high compressive strength and a high density. The cells expand when exposed to heated gas because the cells do not break, and liquid and gas molecules cannot freely travel from cell to cell. Since the expansion in the material is filled, closed-cell foam is an ideal material to use as a heat insulator. Open-cell foam is lighter in weight, spongy, and soft. The surfaces of the bubbles, or the cell walls, are broken, and all the spaces in the material are filled with air. The soft, weak nature of open-cell foam makes the material ideal for foam cushions and foam padding. Open-cell foam is also twice as resistant to sound as its closed-cell counterpart, and can thus be used as an effective sound barrier.

Foam fabricating services work with a variety of types of foam for a multitude of applications. Polyurethane foam is the most commonly used. It is a durable closed-cell foam that can biodegrade in both indirect and direct sunlight. Urethane foam can be found in applications such as insulated containers, flexible foam seating, protective foam padding, insulation foam, EKG pads, x-ray positioning pads, and surgical scrubbers.

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!


Polyethylene foam is flexible, extruded, expanded closed-cell plastic foam. Polyethylene foam is used primarily as a protective material due to its shock-absorbing qualities, and is used extensively in packaging items such as clothing, food, sporting goods, signs, furniture, and computer parts. One particular type of polyethylene foam is known as Ethafoam, which has exceptional shock absorption qualities. Thus, it is frequently used for bracing and cushioning protection in material handling and shipping applications. Another closed-cell foam is Polyether foam. It has adequate acoustic and packaging properties, and is a low-cost foam. PVC foam is a soft and pliable closed-cell foam made from vinyl. It is used in gaskets in order to prevent water transmission. Expanded polystyrene, or EPS, is used for a diverse applications such as padding foam in slippers, insulation foam, oil rigs, filter foam in AC units, satellites, and weather balloons.

A variety of materials can be used to make foam. These include rubber, low-density elastomers, and plastic. Foam is typically formed from polymers mixed with a gassing agent and other chemicals. When the gassing agent is added, the material expands, forming a foam strip that is made up of countless gas bubbles within the material. After making the foam, it can be used in a variety of foam fabricating services such as foam cutting. One type of foam fabricating process is known as die cutting, which involves cutting different shapes out of foam strips, sheets, or blocks. Another process known as water jet cutting fundamentally performs the same function, but utilizes a high-pressure stream of water and is capable of cutting with more precision than die cutting. There are also a few different methods of foam forming, the most popular of which is known as thermal forming. In this process, machining shapes are made by heating the bulk foam materials. Foam felting is another foam forming process in which thick, soft foam materials are compressed and cured in order to form denser foam materials.

In the foam fabricating process, a lot of scrap is produced. The foam die cutting process is the first source in which scrap is produced. Foam scrap can be produced from changes in the manufacturing process, to the shutdown and startup of the production line, to the material left over when shapes are die cutted. The second major source of scrap is when the useful life of foam products has expired. Scrap foam can be rebounded, shredded, and reused for products such as carpet padding, or filler for pillows and other furniture. Another way to dispose of foam scrap would be to burn it; however, this method has decreased in popularity over the past few decades. Although the U.S. government generally considers the burning of foam to be non-toxic, the increase of environmental concerns and stricter regulations regarding carbon dioxide emission have influenced companies to handle foam waste by way of recycling. Once benefit of recycling is that it enables companies to recuperate the return on their investment, which would otherwise be lost if the scrap is burned. Although there has been an increase in use of recyclable foam products, it can be costly and time consuming to collect the foam, separate the contaminants, and ship the foam economically.

American Excelsior Company

American Excelsior CompanyFoam Fabricating – American Excelsior Company