Molded foam has applications in a wide range of industries, including: sports and recreation, lawn and garden, automotive fabricating, footwear and comfort, food processing, construction office, outdoors, mining and bath. Read More…
Leading Manufacturers
American Excelsior Company
Arlington, TX | 800-777-7645The applications for foam fabricating are only limited by one’s imagination; that is our slogan at American Excelsior. We are a foam supplier who offers many different foam cushions & foam padding for over a dozen industries.
American Foam Products
Painesville, OH | 440-352-3434For innovative and cost-effective fabricated foam packaging, American Foam Products should be your preferred vendor! We utilize a wide range of foams and other materials, including polyethylene, polyurethane, crosslink polyethylene, expanded polystyrene and plastic corrugated, as well as a broad range of manufacturing services and capabilities.
Heubach Corporation
Garland, TX | 800-530-0091Our highly advanced foam solution are ideal for a wide range of applications. We take your satisfaction very seriously which is why we offer custom services to accurately manufacture all of your products.
Flextech
St. Louis Park, MN | 952-345-0012As a leader in the foam fabricating industry, FLEXTECH uses a variety of methods to produce your product including compression and encapsulation molding, vacuum forming, laminating, skiving, and die cutting. To guarantee customer satisfaction, every step of production is closely monitored and examined to ensure it meets FLEXTECH’s exacting standards for quality and customer satisfaction. Your requirements are an essential element in the completion of every product and are meticulously followed.
Luxaire Cushion Company
Newton Falls, OH | 330-872-0995At Luxaire, we realize the importance of customer care. No matter how challenging the project, we fabricate our foam with the utmost precision to get it right the first time. Available foams include rigid, semi-rigid, open-cell, and outdoor foam. We are capable of performing detailed fabrication with our cutting-edge CAD production equipment.
Wisconsin Foam Products, Inc.
Madison, WI | 800-989-3626Wisconsin Foam is a foam supplier that serves a multitude of applications & industries with highly targeted, cost-effective precision flexible foam solutions— no matter the size or complexity.
Thrust Industries
Evansville, IN | 800-467-6730Here at Thrust Industries we provide die cut foam that comes in a variety of shapes and configurations. We die cut foam from a number of materials including: urethane, PVC, polyester, neoprene, ether, cellular, volara, and much more.
Packaging Strategies, Inc.
Baltimore, MD | 410-547-7877Packaging Strategies is a leading foam fabricator with over 30 years experience in the design and manufacturing of flexible foam packaging solutions and products. With state of the art in house engineering and computer controlled fabrication machinery PSI has become one of the leading suppliers in the industry. Foams products include flexible polyethylene’s, polyurethanes, cross linked. Specializing in case and container inserts and cushion and vibration analysis PSI is an excellent choice for your next project.
Design Converting, Inc.
Grand Rapids, MI | 616-942-7780Our long-term customers know they can trust us to find them the best deals on foam products. We believe that savings should be passed on. We are not in business simply to make profits, but to benefit our customers with high quality products and services.
Closed Cell Foam - American Excelsior CompanyFabricators can mold polymer foam, such as urethane foam or polyethylene foam, into a wide variety of products, such as: molded foam sheets, bumpers, conveyor bushings, conveyor wheels, pneumatic seals, knee pads, helmet lining, mats and countless other products.
When designing your product, fabricators consider factors like: application environment, required impact resistance, required chemical resistance, required impermeability and more. Based on your application specifications, they can pick a material and a molding method. Each molding method has something a little different to offer.
Injection molding, for example, is inexpensive and capable of producing high volumes of high tolerance, complex parts. Unfortunately, though, the cost of cooling injection dies is quite high in comparison with the rest of the process. Also, the parts often require secondary processing after molding.
Reaction injection molding is unique in that it completes curing while the foam is still inside the mold. The foam, which is first mixed with additives (catalysts, polyols, surfacents, blowing agents, etc.) reaches the mold after fabricators inject it as a liquid. Once the liquid polymer is inside the mold, fabricators use an impinging mixer to pressurize it and give it its final shape. This type of foam molding creates lightweight and strong products, has low tooling costs and requires less clamping force than other molding processes. Its only real drawback is the fact that it has higher than normal raw material costs and high cycle times.
Centrifugal molding involves rotating the polymer material on an axis, where it’s exposed to centrifugal forces that help shape it. Fabricators use centrifugal molding to create products with large cross sections. It, however, is more time consuming than the other foam molding methods.
Whatever method your fabricators choose to make it, molded foam is an excellent investment for many customers. To find out if molded foam is right for you, consult with one or more of the many molded foam fabricators listed on this page.
