Business Details
50+ Years
experience
Your Trusted Partner for Technical Foam Solutions
Foam Engineers has been a leader in technical foam fabrication since 1966, building on a legacy of innovation that began with its parent company Non-Sag Seating in 1928. As a family-run business, we specialise in converting and fabricating bespoke foam solutions for global industries including aerospace, military, medical, and environmental sectors. Our 4,000m manufacturing facility in High Wycombe, Buckinghamshire, houses advanced CNC routing, thermo-forming, and die-cutting technologies, enabling precision engineering of complex foam components.With ISO 9001:2015 certification and a commitment to sustainability through recycled and bio-based materials, we combine technical expertise with a client-focused approach. Our team of engineers and designers delivers tailored solutions, supported by rapid prototyping and a four-day working week to reduce environmental impact. Recognised as the UKs sole supplier of military-specification explosion suppressant foam, we maintain a reputation for reliability, innovation, and quality in safety-critical applications.
Services
CNC Foam Routing
Explosion Suppressant Foam
Custom Foam Fabrication
Thermo-Formed Components
Die-Cut Foam Shapes
Reticulated Filter Foams
Closed Cell Polyethylene Foam
Open Cell Polyurethane Foam
Eco-Friendly Foam Solutions
3D Machined Foam Products
Details
- Year established: 1966
Highlights and features
- We offer bespoke foam fabrication with ISO 9001-certified quality assurance.
- Our technical expertise spans 50+ years in safety-critical foam applications.
- We utilise advanced CNC and thermo-forming technologies for precision engineering.
- We provide rapid prototyping and global material sourcing capabilities.
- Our sustainability program includes 30-100% recycled and bio-based foam options.
Associations and certifications
- ISO 9001:2015
What people say
Award-winning service
ISO certified quality
Bespoke solutions
Innovative designs
Global reach
Services
CNC Foam Routing
Our CNC routing technology enables 3D machining of complex foam shapes with 0.5mm accuracy. Using 5-axis capabilities, we produce technical components for aerospace and motorsport industries. The process supports materials up to 2.5m in volume, ensuring dimensional stability for safety-critical applications.
Explosion Suppressant Foam
We manufacture MIL-PRF-87260B compliant explosion suppressant foam for aircraft and military fuel tanks. This reticulated polyurethane foam prevents vapour ignition while maintaining fuel system functionality. Installation kits include pre-cut components with fuel-wetting properties for secure fitment.
Eco-Friendly Foam Solutions
Our range includes 30-100% recycled polyethylene, bio-based polyurethane from castor oil, and compostable corn starch foams. These materials meet industry standards while reducing petroleum dependency. We also offer closed-loop recycling for production waste into secondary products like carpet underlay.
Thermo-Formed Components
Thermo-forming processes create contoured foam parts for medical, packaging, and automotive sectors. Sheets heated to 180C are vacuum-formed into moulds with 1mm tolerance. This method produces lightweight, durable components with custom surface textures and density gradients.
Die-Cut Foam Shapes
Laser-cut steel dies produce repeatable foam components with 0.1mm edge consistency. We process sheets up to 100mm thickness across polyurethane, polyethylene, and reticulated materials. Applications include gaskets, spacers, and custom packaging inserts for electronics and aerospace sectors.
Questions
What industries do Foam Engineers supply?
We serve aerospace, military, medical, automotive, electronics, and environmental sectors with technical foam solutions.
Are Foam Engineers' products certified?
Yes, we hold ISO 9001:2015 certification and manufacture to military specifications including MIL-PRF-87260B.
Can you create custom foam designs?
Our team provides bespoke foam fabrication using CAD software and rapid prototyping for unique applications.
Do you offer sustainable foam options?
We supply 30-100% recycled polyethylene, bio-based polyurethane, and compostable foam materials.
What manufacturing capabilities do you have?
Our facility includes CNC routing, thermo-forming, die-cutting, and laminating for complex foam components.
How quickly can you deliver orders?
We maintain a four-day working week with standard lead times of 5-10 working days for custom orders.
