How We Serve You

United Foam operates 8 strategically located manufacturing facilities throughout the US.

Are you looking for a foam solution? United Foam is here to help! We can guide you through the entire process from conceptual design and material selection right through to production implementation. We have the capabilities to meet your project's requirements with our creative designs, vast materials selection, proprietary processes, in-house tooling and multi-disciplined engineering staff. Learn more on our Services page.

When we receive a project to work on it typically goes through the following steps:

  • Evaluation:
    We pride ourselves in being objective consultants with each new project. We can help determine what material(s) best suits your needs. If we feel we cannot deliver a finished product that meets your expectations with our materials and processes, we will suggest another direction for your project, even if it is not with United Foam.
  • Determine Project Specifics:
    Project specifics are reviewed including: a clear understanding how the part will be used, critical design elements, what materials will be used, how the product will be manufactured, quality requirements and projected volumes etc.
  • Engineering Estimate:
    With an idea of the annual usage along with an understanding of the dimensions, materials and proposed processing methods for the part, we can estimate product cost.
  • Design Concepts:
    We will create conceptual designs called Development Drawings using the latest in CAD software including AutoCad, SolidWorks® and MasterCam. This is a collaborative process between the customer and our engineering and sales teams.
  • Prototype Tooling:
    United Foam has a number of different prototyping options available depending on the manufacturing method used to produce the part. This includes, steel rule dies, punch dies, vacuum forming molds, compression molds etc.
  • Samples, Testing & First Article Approval:
    Once the prototype tool is complete we are ready to manufacture samples. The samples are either submitted to the client for evaluation and testing and to ensure the samples meet the design intent or United Foam will use its UPS certified package testing lab if it is a protective packaging application.  We also offer other outsourced testing capabilities. 
  • Design Finalization:
    Once the samples have been approved and an order is placed for production tooling and parts, we are ready to manufacture production tooling.
  • Production Tooling:
    Production tooling from United Foam ranges from simple cutting dies to precision CNC machined molds. Our in-house design and tooling facilities allow us to maintain strict control over the process, which provides outstanding quality and a flexibility to meet tight deadlines.