Engineered Foam

Both lightweight and strong, engineered foam is used for a wide range of purposes due to its affordability and ease to manipulate for complicated projects.

Engineered foam is often made from Polystyrene, flexible polyurethane or polyethylene. These materials can be produced in a range of densities, colours and sizes, making them ideal for anything from insulation sheets, to producing bespoke packaging for protecting delicate items, such as electronics – which will benefit from the scratch and vibration protection engineered foam provides.

Other uses include car polishing pads, sponges, filter elements, sanding pads and microphone windshields.

The ‘engineered’ element of the name comes from the material’s ability to be easily shaped using a variety of options. These include moulding, CAD/CAM and CNC machining or waterjet. This versatility and ease of manufacture means that complicated shapes can be produced at a range of densities, affordably and with a short lead-in time.



Popular Applications

  • Automotive – for components including headrests
  • Construction – including insulated floor and wall panels
  • Packaging – protective packaging for transport and storage of fragile items
  • Filters – for the construction of filter elements

What We Offer

At Technical Foam Services and Custom Foams, many of the engineered parts we produce are in flexible polyurethane, polyethylene, EPDM or a combination of these materials.

One of our great strengths is that we have our own engineering team who design and manufacture tooling and bespoke machinery/processes – something many in the industry cannot offer. In addition to CAM, moulding and waterjet cutting, we can also buff, grind and bore foam to get it to the exact specifications for your project..

Read our CAD guide to find out more about its benefits for prototyping and design.

Both Technical Foam Services and Custom Foams pride ourselves on developing foam products of any size and shape to meet every specification. As leading providers of foam cut to size, we have built our vast knowledge and converting capabilities to ensure that we can provide the perfect material, whatever the requirements of the project.

Why choose us?

High-quality, high-tech solutions with no-nonsense guidance, competitive pricing and 100% customer satisfaction.

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Foam design and development

We’re not just manufacturers – we offer support and guidance with bespoke foam design and development.

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Expertise in foam materials

We have an outstanding reputation in the field of specialist foam and can recommend the right solutions to meet your needs.

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What are the key properties of engineered foam?

Engineered foam can be manufactured in a variety of shapes and densities. Some of the key properties which make it such a popular choice include:

  • Insulation
  • Buoyancy
  • Flexibility
  • Filtration

What are the benefits of engineered foam?

Some of the main benefits of using engineered foam include:

  • The wide range of structural properties available (densities, finishes, colours)
  • Low cost
  • Tooling and finishing are simple, making complex shapes achievable.
  • Recyclable

What types of foam is engineered foam made from?

Engineered foam is typically made from one of the following types of foam:

  • Flexible polyurethane (FPU)
  • Polyethylene (PE)
  • Polystyrene (EPS)
  • Expanded polypropylene (EPP)
  • Expanded polyethylene (EPE)

Are engineered foams eco-friendly?

Both polyurethane and polyethylene can be recycled.


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