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Custom Foam Fabrication

Foam Fabrication | UFP Technologies

As one of the leading foam fabricators in the United States for over 50 years, UFP Technologies has the knowledge, experience, and technology to satisfy your most challenging foam component, packaging and product needs. We have multiple facilities throughout the country equipped with the most advanced foam fabrication capabilities including compression molding, CNC routing, and die-cutting. Our capabilities allow us cut, shape and mold a variety of foam materials to produce custom precision parts. We also have the ability to form or bond foams with other materials to create performance composites for specific applications.

Our manufacturing capabilities combined with our access to an array of foam materials gives us the ability to create custom precision foam solutions that best fit your needs. Our foam fabrication capabilities include the following:

CNC Routing

Computer numerically controlled (CNC) routing is a manufacturing process which uses computer guided drill-bits for cutting, shaping and carving materials. Utilizing CNC routing with foams, plastics or other specialty materials can produce complex precision parts without the need of custom tooling.

Water Jet Cutting

Water jet cutting uses a jet of water at high-velocity and pressure to cut, shape and carve materials. Water jet cutting provides precisions cuts with no particulate issues. Water jet cutting is utilized on a variety of applications ranging from foam and plastic tool control trays to foam inserts for protective cases.

Compression Molding

Compression molding is a manufacturing process in which materials are molded into three-dimensional shapes using heat and pressure. Compression molding is utilized as a fabrication method when contoured shapes are needed. We extensively use compression molding on projects that require composite materials.


UFP Technologies has extensive experience laminating fabrics and foams. Laminating is used when there is a need to create composite materials, which is the combination of multiple materials (such as foam-to-fabric and foam-to-foam). We offer a range of lamination capabilities including flame, heat and adhesive.

Die Cutting

Die cutting is a fabrication process to cut and shape materials using various types of tooling and high tonnage presses. Our facilities have extensive die cutting capabilities including high speed, optically registered, kiss cutting, rotary and vacuum systems.