Foam Fabrication

Foam Molders & Specialties is the leading foam fabricator for high-performing custom and standard solutions. These include, but are by no means limited to reticulated polyurethane, cross linked polyethylene, and EVA foam. 

As a custom converter, every project is created to your exact specifications. With a product concept in hand, we can help finalize your design and create the prototype, as well as the necessary tooling, for full-scale product manufacturing. 

As a true turnkey supplier in all aspects of foam fabrication, you can choose FMS with confidence as your next choice in a fabricating partner.

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Processes

Performing numerous foam fabrication processes, we can produce a variety of parts. From gaskets, padding, insulation, packing, cushioning and filtration, the uses are endless. If you have a specific application in mind, we can engineer the solution that you need to meet your requirements. 

With a variety of the industry’s most innovative equipment on hand, FMS can handle any fabricated foam project. We purchase commercially available foam blocks, planks, and rolls, and then cut them into any thickness or shape you desire. With horizontal and vertical precision saws, we can cut foam down to 1/16” and still maintain its integrity.

Die Cutting
With a variety of die presses, FMS can combine and form sheets of foam into any shape you desire. If you have a specific shape that requires a custom die, we can create one that is for your exact project needs.

Hot Wire Cutting

Some projects require a special method that utilizes a hot wire to cut cavities and contours in foam. It is used for applications such as case liners, or parts needing a clean precise edge. This process ensures a tight and snug fit for both enhanced aesthetics and performance. 

Heat Sealing

This process compresses foam into a permanent set for a variety of uses such as instrument organizers for medical operating rooms, cleaning filters, and more. Custom shapes can be created for specific product models and nonstandard-sized equipment. 

Slitting / Splitting

We purchase commercially available foam blocks, planks, and rolls, then cut them into any thickness or shape you desire. With horizontal and vertical precision saws, we can cut foam down to 1/16” and still maintain its integrity.

Thermal Forming

There are many applications for thermoforming process.  By applying heat to the material, we are able to shape EVA material into products ranging from protective padding for athletes, to pouches for medical foam products.

Other processes available:

  • Grinding / Buffing
  • Compression forming
  • Specialty fabricating
  • Convoluting
  • Custom assemblies

Types of Foam

We offer a wide variety of high quality foams that serve several different markets. If you have an application that requires foam, we can analyze your project and provide you a material solution either from the foams we have in stock or source your specific requirements.

If you need material recommendations for your project, we can assist you in determining the best solution for your application. Give our experts a call any time for a consultation on the right type of foam necessary for your specifications. 

Foam types that we carry include but are not limited to:

Other processes available:

  • Reticulated Foam
  • Non-reticulated Foam
  • Filter Foam
  • Crosslink Polyethelene Foam
  • Polyether Foam
  • Polyester Foam
  • Polyurethane Foam
  • ELE Foams
  • Sponges
  • Polyethelene Foam
  • Neoprene Foam
  • Comfort Foam
  • Double Cell Foam

Markets Served

Foam products are all around us.  You might find them in your car, computer, and in medical applications. 

We offer solutions to your ideas and can help you bring new and innovative products to the marketplace. If you don’t see your market listed below, “give us a foam call”. We welcome the opportunity to enter into new industries.

  • Aircraft
  • Automotive
  • Electronic
  • Medical
  • Military
  • Recreation

Products / Applications

Foam has unique and versatile properties that can be achieved by foam molding or fabrication.  We provide thermal impact and abrasion protection for the most fragile items. 

FMS has a wide range of high and low-density polyurethane foams that can be fabricated or custom molded to meet your strictest requirements. The products we produce cover a wide variety of applications.  All are custom-made to your specific needs.

Some applications we have successfully developed solutions for the in the past include: 

  • Seating
  • Cushions
  • Filtration
  • Explosion
  • Suppression
  • Fuel tank inserts
  • Packaging
  • Wicking
  • Reservoirs
  • Inkjet cartridges
  • Attenuation of sound
  • Sponges
  • Outdoor furniture
  • Insulation
  • Structural
  • Gasket sealing
  • Decorative
  • Electronics packaging
  • Specialty

If you do not see your general application listed above, that does not mean we have not served your industry in the past. Contact us anytime to ask us about our experience with specific use cases. 

Tooling

Our talented and diverse group of engineers, technicians, and sales experts will work with you to create the proper tooling for your job. Depending on the process, the required tooling may be comprised of:

  • Steel / Aluminum
  • Wood / Steel
  • Wood / Brass
  • All Steel
  • Wood / Steel rule die
Foam Conversion Die Cut Tooling

With tooling on hand we are ready to go into production. If changes in tooling are required, we can make the necessary changes. This allows quicker turn around times and helps avoid needless delays.

Case Studies

Flexible Foam

Thanks to foam’s versatile applicability,  we have one to fit for your application. Flexible reticulated foam comes in various densities, allowing it to be used for filters, sponges, auto detail pads and many other uses. 

We welcome small foam parts produced in large quantities.  In this application, the client uses both the inside and outside of the parts that are die-cut. This is achieved by designing the tooling that can accomplish both tasks.

Custom Packaging Inserts

From time to time our clients are faced with a custom packaging needs. Whether it is a delicate medical instrument that needs protection during storage or an item that needs special care during shipping, we have a wide selection of foam in stock and talented technicians that can help configure an insert to fit your requirements. 

We can perform all the processes necessary (die cutting, laminating, hot wire cutting) and the various assemblies to complete the application. This results in a fully finished product that is ready for use. Our manufacturing capabilities allow us to produce large and small batches or custom-specific quantities.

Medical Instrument Protection

In the medical industry, unclean equipment can pose a number of risks, such as infection or even death. Instruments need to be handled with great care so that they can continue to perform as designed and maintain safety for medical staff and patients. 

Custom-fabricated foam allows parts to be securely placed in pockets for cleaning and sterilization. The part is cut to size and heat-sealed to form pockets strong enough to securely hold them in place.  Because the design allows a complete enclosure around the equipment the proper cleaning can be attained. This is one of the many uses and benefits of using medical foam products.

Air Filter

Custom foam solutions are popular and immensely beneficial to the automotive industry. A number of processes are used in creating air filters for motor vehicles. 

Air filters are cut to size, die-cut, formed, shaped, and finally, hot wire cut to produce a finished product. Because we offer all of this in-house, we are able to complete a fully manufactured solution in-house in a single facility.  This part uses two types of foam that nest together.  We are truly a “one stop shop”.

Leg Core

Because of the different densities and make-up of foam, it covers a wide variety of applications. By buffing and grinding a non-reticulated piece of foam, we are able to produce a lightweight insert that can be used as the inner part of a prosthesis used for an artificial leg. Having the density to conform makes it easier to fit the part to the patient.

Audio Equipment 

Foam plays an instrumental role in audio equipment. From microphone covers to speakers and guitar cases, foam can help improve acoustic control and enhance sound quality. Foam layers can either be built into the speaker housing or offered as an aftermarket addition. Hardshell cases can also be lined with foam in a general shape or custom-fitted to a specific model of instrument. 

We Are Leading Custom Foam Fabricators in California

Many industries rely on foam components for their products, requiring custom foam fabricators in California to complete their orders. Foam Molders & Specialties offers specialty fabrication to your exact specifications using high-quality foam, including reticulated polyurethane, EVA foam, and cross-linked polyurethane. Our team uses a custom converter to create a prototype for your approval. Once you approve our design, we’ll complete your order.

We Use State-of-the-Art Processes

We use many custom foam fabrication techniques to develop your required components. Whether you need cutters foam fabrication or another specialty fabrication, we have the necessary equipment and knowledge to complete your order. We use die cutting, hot wire cutting, heat sealing, slitting/splitting, and thermal forming, among other processes. Our team recommends the appropriate solutions to create your required components. You choose your foam type and give us your specifications, and we’ll handle the rest.

We Provide Solutions for Many Applications

Our custom foam fabricators in California work with you to choose the most appropriate foam type and process to create what you need. We proudly serve various industries, including medical, automotive, aviation, electronics, military, and recreation, with products for numerous applications, such as cushions, suppression, gasket sealing, reservoirs, insulation, electronics packaging, and much more. We can create anything you imagine.

Contact us today to discuss the specifics of your project with our custom foam fabricators.

Our Capabilities

Work with America’s Leading Foam Fabricators for Your Project

Have a project on the horizon that requires a custom foam solution? We are here to help you develop the right material for your exact specifications. Contact us today to speak with one of our foam design and fabrication experts.

FAQs

Foam fabrication creates custom foam products using various foam materials and fabrication techniques. It involves cutting, shaping, and forming foam materials into specific shapes and sizes to develop numerous products.
Various kinds of foam materials are used in foam fabrication, including polyurethane, polyethylene, and polystyrene foam. These foams come in different densities and can be customized to meet strength, durability, and insulation requirements.
Some common methods used in foam fabrication include CNC cutting, die-cutting, water jet cutting, and compression molding. These techniques allow for the precise cutting and shaping of foam materials to create custom products that meet design and performance requirements.
Foam fabrication is used in many industries, including automotive, aerospace, packaging, construction, and medical. Foam products are used in various applications, such as cushioning, insulation, soundproofing, and protective packaging.
Foam fabrication offers several benefits, including customization, durability, and cost-effectiveness. Foam products can be tailored to meet design and performance requirements, and they are lightweight, easy to handle, and resistant to moisture and chemicals. Foam fabrication is also a cost-effective way to produce high-quality products in large quantities.
Yes, foam products can be customized to meet design and performance requirements. Foam materials can be cut, shaped, and formed to create products in various sizes, shapes, and densities. Customization options include color, texture, and printing, allowing for branding and marketing opportunities.