Foam Inc.

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Aurora, IL  |  844-362-6462

At Foam Inc., we define ourselves as dedicated foam fabricators focused on delivering materials and components that offer precision, consistency, and reliable performance across a wide range of applications. We work with an extensive selection of foam types and densities, giving us the flexibility to create solutions that support cushioning, insulation, protection, filtration, and structural needs. Through careful material sourcing and controlled fabrication processes, we produce foam products that meet strict dimensional, mechanical, and functional requirements.

We approach every project with a collaborative mindset, helping customers refine their designs and select the ideal foam for their application. Our capabilities include cutting, shaping, laminating, bonding, and custom assembly, allowing us to produce everything from simple pads to highly engineered components. By understanding how foam behaves under compression, impact, and environmental exposure, we guide our customers toward solutions that balance performance with cost and long-term durability. Our internal quality standards ensure that every part integrates smoothly into downstream assembly or end-use environments.

Foam Fabricating Power Pages

Closed Cell Foam

Closed Cell Foam

Closed cell foam is a type of foam where the “cells” are tightly pressed together and enclosed, contrasting with the open, traditional polyurethane foam variation or interconnected cells of the open cell…

Polyethylene Foam

Polyethylene Foam

Polyethylene foam is a valuable closed-cell thermoplastic foam material. A closed-cell foam consists of tiny dense cells enclosed by its walls. The cells sit close to each other, but they are not interconnected. Hence, closed-cell foams like…

Polyurethane Foam

Polyurethane Foam

Polyurethane foam is a porous, cellular-structured, synthetic material made from the reaction of polyols and diisocyanates. Its structure is a composite of a solid phase and a gas phase. The solid phase is made from…

Thermoforming Foam

Thermoforming Process Types

Thermoform foam is a shaping process where sheets of spongy foam are heated until they are pliable for forming. Once the forming temperature is reached, the sheets are placed in or on a mold to be formed to a specific shape using molding…

Die Cutting

Basic Die Cutting Process

Die cutting is a mass fabrication process for cutting out shapes by shearing stock materials such as paper and chipboard using a die, which is a specially crafted tool used for cutting or shaping a material. The die has sharp…

Kiss Cutting

Kiss Cutting

Kiss cutting is a method for cutting into a material where the upper layers are pierced, but the back layer is left intact. The term "kiss" refers to the way the blade touches the upper layers of the material and leaves a pattern or cut with a sufficient amount of force to leave an impression…

Plastic Fabrication

Plastic Fabrication

Plastic fabrication is the process of designing, manufacturing, and assembling a product made out of plastic material or composites that contain plastic. There are numerous plastic fabrication methods known today, considering the wide variety of products made out of plastic…

Plastic Materials

Plastic Materials

Plastic materials are objects artificially made from organic compounds called polymers along with other additive components. They possess excellent formability, making them extremely versatile for many different fabrication and manufacturing processes…

Plastic Extrusion

Plastic Extrusion

Plastic extrusion, also known as plasticating extrusion, is a continuous high volume manufacturing process in which a thermoplastic material — in a form of powder, pellets or granulates — is homogeneously melted and then forced out of the shaping die by means of pressure…

Die Cutting Services

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