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Foam Packaging Manufacturers

Last updated: January 2026

This directory lists 113 foam packaging manufacturers across the United States, from regional custom fabricators specializing in low-volume runs and specialized materials like Volara to integrated national suppliers offering high-volume molded solutions and comprehensive ISTA testing.

Buyers in this category are typically solving critical problems such as minimizing product damage during shipping, meeting stringent regulatory requirements for medical devices, or optimizing supply chain costs by reducing package weight while maintaining superior shock absorption and resiliency. The choice of foam — from polyurethane to cross-linked polyethylene (XLPE) or Ethafoam — is paramount to achieving these specific performance metrics.

Suppliers in this space generally fall into a few key types: custom fabricators who excel at die-cutting, waterjet cutting, and laminating diverse foam types for lower volumes and intricate designs; molded foam specialists focusing on high-volume expanded materials like EPP or EPS for complex, repeatable geometries; and full-service providers who offer design engineering, rapid prototyping, and in-house performance testing alongside manufacturing.

To engage effectively with these manufacturers, buyers should arrive prepared with detailed CAD models (preferably STEP or IGES files) of their product, target g-force requirements for impact protection, anticipated annual volumes, and any specific environmental or regulatory compliance needs such as RoHS or REACH. This level of detail enables suppliers to accurately quote and recommend optimal material densities and fabrication processes.

A notable trend in foam packaging is the increasing demand for sustainable solutions, driving manufacturers to innovate with recycled content foams, bio-based materials, and designs optimized for returnable dunnage. The focus is shifting towards circular economy principles, balancing protective performance with environmental stewardship without compromising critical factors like compression set resistance over time.

113 companies·80 emails·107 phones

Company Directory

113 companies nationwide

Gardena, CA

Based in Gardena, CA, Advanced Foam Packaging specializes in custom foam packaging design and fabrication. They provide anti-impact foam solutions for diverse projects, utilizing their workshop for custom fabrication. The company also produces foam props for movie sets, architectural decorations, and other specialty foam items.

Houston, TX

Atlas Industrial Supply, Inc. specializes in custom foam solutions for protective packaging needs. They provide precision-cut foam inserts for transporting, storage, and shipping, often integrating with leading case brands like Pelican, SKB, and Nanuk. Their services ensure optimal protection and organization for industrial and commercial items.

Albany Foam and Supply, Inc. is a family-owned business specializing in foam fabrication for packaging and various applications. They manufacture and provide rebond, latex, mid, and ultra foam types. With over fifty employees, their factory ensures efficient service and shipping of fabricated foam materials.

Alleguard provides custom foam solutions, including protective packaging for various industries. The company specializes in engineering, delivery, and service of foam products for construction, cold-chain, and packaging applications. They operate an integrated network of manufacturing and logistics hubs to serve businesses.

Minneapolis, MN

Amcon Foam Fabrication provides end-to-end foam fabrication for industrial manufacturers. Since 1976, they offer design, engineering, material selection, and production for diverse foam needs, handling high-volume and small quantity projects. Utilizing over 80 foam classifications, they operate from facilities in Minnesota and Colorado.

Arlington, TX

American Excelsior Company manufactures flexible foam products specifically designed for packaging, cushioning, and various engineered foam specialties. The company also produces materials for erosion control and a range of wood fibers. Operating within the United States, it provides solutions for industrial and commercial applications.

Painesville, OH

Based in Painesville, OH, American Foam Products manufactures custom foam packaging and case inserts. With nearly 50 years of experience, they offer end-to-end protective solutions, from design to delivery. They specialize in fabricated foam for diverse applications like box inserts, cases, and electronics industry needs.

Sylmar, CA

Based in Sylmar, California, Atlas Foam Products specializes in manufacturing custom shock-protection packaging solutions. They utilize polyurethane, polyethylene (Ethafoam, Stratocell), expanded polystyrene (EPS), and cross-linked polyethylene foams. The company offers over 100 foam formulations, providing tailored packaging solutions for corporations and diverse industries.

Rancho Santa Margarita, CA

Based in Rancho Santa Margarita, CA, BlueRose Packaging manufactures custom EPE foam sheets, specializing in optimal product protection. They provide customized foam solutions to secure fragile items during shipping, alongside custom wooden crates, personalized boxes, and durable bubble rolls for diverse packaging needs.

Anaheim, CA

Based in Anaheim, CA, Brown Packaging manufactures custom foam inserts and diverse packaging solutions for businesses. With over 30 years of experience, they provide in-house structural design and a wide range of material options. They offer both custom and stock packaging, guiding clients from concept to completion as an ISO 9001:2015 Certified provider.

Ontario, CA

Based in Ontario, CA, California Packaging & Display manufactures diverse packaging solutions. They specialize in cushioning materials like expanded foam, cushion foam, and anti-static foam for product protection. The company also offers blister cards, skin packaging, bubble wrap, and poly bags, providing comprehensive custom packaging services.

Napa, CA

Based in Napa, CA, Cartons & Crates designs and manufactures custom packaging solutions. They specialize in creating protective packaging, including thick, soft foam pillows, to secure delicate items like artwork during transit.

Anaheim, CA

Based in Anaheim, CA, Case Club manufactures custom foam inserts for hard shell cases. They provide precision laser-cut foam solutions, ideal for diverse product lines and sales teams. Their in-house capabilities ensure tailored packaging with various foam types and interior options for commercial applications.

Atlanta, GA

Cellofoam manufactures custom molded and fabricated protective packaging solutions using EPS foam. They engineer lightweight yet strong packaging and components for various products, ensuring safety through the supply chain. The company also offers Perma Cool® insulated shippers and gel packs, providing essential cold chain protection.

Clyde, OH

Based in Clyde, OH, Clyde Foam LLC has manufactured Expanded Polystyrene (EPS) foam solutions since 1967. The company specializes in providing lightweight, rigid, and insulating EPS foam for various industries. This includes creating custom protective packaging and structural components tailored to specific client applications.

Sylmar, CA

Based in Sylmar, CA, Cobra Foam Inserts and Cases specializes in manufacturing custom cut and replacement foam inserts for protective cases and dry boxes. They offer a wide selection of foam solutions, are Made in the USA, and ship worldwide.

Westerville, OH

Based in Westerville, OH, Columbus Foam Products, Inc. manufactures custom foam solutions and protective padding. They provide custom cutting services ideal for safeguarding sensitive products during transit and for various industrial applications. With 30 years of expertise, they serve residential and commercial customers, also offering athletic equipment and dock seals.

Camarillo, CA

Based in Camarillo, CA, CPSupply specializes in molded foam and thermoformed packaging solutions. The company provides materials and services crucial for cold chain logistics and other specialized packaging needs, emphasizing sustainability and education within the industry.

Conroe, TX

Based in Conroe, TX, Custom Packaging Products engineers custom foam solutions for protective packaging, especially within electronics manufacturing. This nationwide industrial packaging supplier provides high-volume materials and turnkey solutions. Their offerings include custom foam, corrugated boxes, and poly bags for commercial clients.

Houston, TX

Custom Foam Parts, based in Houston, TX, manufactures high-precision custom foam inserts for diverse applications like shipping, display, and retail packaging. They offer various foam types, including ESD-safe and waterproof, with logo branding and precision cutting methods for industries such as aerospace and electronics.

Troy, MI

Envirolite, LLC, based in Troy, MI, is a custom foam fabricator specializing in polyethylene foam solutions. They produce cushioning and support foams for fragile or heavy items, meeting FDA standards for indirect food contact. Serving medical, athletic, industrial, marine, and recreation industries, Envirolite delivers reliable, custom-engineered foam products.

Elkhart, IN

Exemplary Foam, based in Elkhart, IN, specializes in custom foam fabrication and plastic components for returnable and expendable packaging. They provide waterjet, die, and dieless cutting services, utilizing materials such as XLPE and EPP/EPE. The company serves aerospace, automotive, electronics, and military industries.

Berkeley, CA

Based in Berkeley, California, Famous Foam Factory has been providing cushioning foam since 1968. The company specializes in producing high-quality foam products for various applications, likely including packaging needs. They focus on delivering durable and effective foam solutions to their customers.

Rogers, MN

Based in Rogers, MN, Foam Industries manufactures innovative packaging solutions. They utilize the proven effectiveness of foam, wood, and plastics to create custom products. The company combines these materials to develop advanced packaging tailored for industrial and commercial applications.

Cleveland, OH

Foam Seal, Inc. manufactures custom PVC foam in Cleveland, OH, available in various colors, densities, and dimensions. Their closed-cell foams cushion against shock, vibration, and seal out moisture. Resistant to chemicals and fire, these sulfur-free, low-VOC foams meet FMVSS 302 and are Prop 65 compliant for industrial applications.

Bell, CA

Based in Bell, CA, Foam Brothers Inc. is a custom foam fabricator specializing in producing packing foam. The company offers custom-cut foam in various shapes and dimensions, catering to diverse packaging needs for industrial and commercial clients.

Grand Rapids, MI

Based in Grand Rapids, MI, Premier Protective Packaging specializes in custom protective packaging solutions. The company manufactures a range of products including Polyethylene (PE) foam, bubble, and spun bond polypropylene packaging in various forms like bags, sheets, tubing, and rolls for diverse applications.

West Chester Township, OH

Foam Concepts & Design, Inc. specializes in the design and fabrication of custom foam packaging solutions for various products. Based in West Chester Township, OH, the company offers comprehensive services, guiding clients from initial concept and design to production and delivery. They focus on tailored packaging to meet specific protection and budget needs.

Hayward, CA

Based in Hayward, CA, Foam Distributors, Inc. is a full-service foam fabricator. They provide design and testing capabilities for cushion packaging using Polyurethane, Polyethylene, and Polystyrene foams. The company serves the Silicon Valley computer, communication, medical, and automotive industries in a J.I.T. environment.

Burbank, CA

Based in Burbank, CA, Foam Mart has provided foam products and services since 1963. They specialize in custom foam solutions for diverse industries, including packaging, cases, upholstery, construction, and audio. Foam Mart offers a wide variety of foams to meet specific industrial and retail needs.

Cerritos, CA

Based in Cerritos, CA, Foam Molders specializes in custom foam fabrication and conversion services. They provide expert foam cutting, shaping, and thermal forming to meet diverse project specifications. The company partners with various industries, including OEM companies, delivering tailored foam solutions.

Oshkosh, WI

Based in Oshkosh, WI, Fox Custom Foam, LLC provides custom foam solutions for various industries, including automotive, electronics, and consumer goods. They specialize in packaging customization, protective cushioning, and vibration mitigation. Utilizing cutting-edge technology, they craft custom foam products for diverse applications, ensuring efficiency and durability.

Foam Products Corporation manufactures and fabricates custom and standard foam products for commercial and industrial customers. The company provides engineered foam solutions for insulation and packaging needs, utilizing capabilities such as custom cutting, die cutting, and CNC routing.

Arlington, TX

Based in Arlington, TX, Geofoam America manufactures expanded polystyrene (EPS) foam products. The company provides high-quality custom packaging solutions, creating various shapes and sizes for manufacturers. They also supply geofoam blocks for construction, flotation logs, and effective foam insulation.

Go Packaging Store offers foam packaging solutions with over 25 years of experience in Foam in Place Packing. The company utilizes proven foam packaging techniques to ensure item safety. Operating as a franchise system, it provides comprehensive packaging services across the United States.

Richardson, TX

General Packaging Corporation manufactures custom foam inserts and assemblies in various densities and materials. Based in Texas, the company provides engineered foam cushioning solutions designed to fully protect products. They offer integrated packaging solutions for diverse industries, alongside corrugated and wood packaging.

Grand Rapids, MI

Grand Rapids Foam Technologies (GRFT) is a family-owned, ISO9001/2015 certified polyurethane foam manufacturer based in Grand Rapids, MI. With over 75 years of expertise, GRFT provides custom molded foam systems and fabrication. They offer a comprehensive range of polyurethane solutions, including cut foam and specialized chemistries for various industries.

Grandville, MI

Based in Grandville, MI, Harbor Foam is a manufacturer specializing in expanded polystyrene (EPS) products. The company provides innovative foam solutions and high-quality materials, catering to diverse industries such as construction, packaging, recreational vehicles, and geofoam applications.

San Antonio, TX

Based in San Antonio, TX, HFP is a full-service design and manufacturing firm specializing in custom foam packaging. They utilize expanded polystyrene, polyethylene, and polyurethane foams to create tailored cushion and cold chain solutions. HFP provides engineered packaging for various commercial and industrial applications.

Houston Custom Foam manufactures custom foam inserts and cases for diverse applications, including packaging, firearms, cameras, tools, and electronics. They utilize CNC equipment to produce perfectly fitted foam case liners from digitized item measurements, providing tailored storage and transport solutions for various industries.

Milton, NH

Index Packaging, Inc. fabricates custom PE, PU, and EPS foam packaging inserts. This New England-based company manufactures custom boxes, crates, cases, and foam inserts, providing comprehensive protective packaging solutions for shipping. They offer fast turnaround and reliable delivery nationwide.

Rollinsford, NH

Based in Rollinsford, NH, Janco Medical is a contract manufacturer specializing in custom foam fabrication and plastic thermoforming for medical and industrial packaging. They provide cleanroom manufacturing, assembly, and packaging services, ensuring products meet stringent regulatory requirements. Janco offers expert assistance from material selection, including Volara and Zote foam, to prototyping.

Orange, CA

Based in Orange, CA, J.D. Packaging Group, Inc. offers full-service packaging solutions for commercial, government, and overseas shipping needs. This family-owned company, operating since 1974, specializes in cost-effective foam packaging, custom wood packaging, and various shipping supplies.

Redondo Beach, CA

Based in Redondo Beach, CA, LA Custom Packaging Design & Supply creates custom packaging solutions for retail and industrial clients. They manufacture foam box inserts and pads, utilizing materials like PE, PU, EPS, EPE, EPP, Minicell, and Crosslink. The company also provides custom rigid, chipboard, and corrugated boxes.

Milpitas, CA

Larson Packaging Company (LPC) specializes in designing and manufacturing foam packaging solutions. Based in Milpitas, CA, the company creates a range of foam packaging, from simple end caps to complex cushioning systems. LPC serves various applications, providing protective solutions for diverse products and industries.

Michigan Foam Products LLC is an expanded polystyrene (EPS) manufacturer based in Wyoming, MI. The company designs and fabricates custom EPS blocks and shapes, providing foam packaging solutions for various industries. They offer engineering design assistance and advanced production capabilities for diverse manufacturing needs.

Anaheim, CA

Based in Anaheim, CA, Mister Packaging specializes in military and commercial product packaging. The company provides foam fabrication services like convoluting, saw cutting, and die-cutting. They focus on custom design, compliance with MIL-STD-2073, and quick turn-arounds for Southern California clients.

Paterson, NJ

Based in Paterson, NJ, MyCaseBuilder specializes in manufacturing custom foam inserts and case solutions. They offer personalized foam packaging from single pieces to high volumes, including full-color printing directly on foam. With over 35 years of experience, they provide advanced design and production capabilities.

Memphis, TN

Based in Memphis, TN, New-Tech Packaging designs and manufactures custom-fit foam packaging for shock, surface, and insulative product protection. The company also provides a wide range of custom and stock packaging products, contract packaging solutions, and packaging automation equipment for various industries.

Anaheim, CA

Based in Anaheim, CA, OEM Materials designs and manufactures precision-engineered foam packaging solutions. They offer die-cut inserts, molded EPS, EPE/EPP, polyurethane, polyethylene, and crosslinked XLPE components. Serving OEMs, aerospace, medical, electronics, and industrial manufacturers, they protect sensitive, high-value products.

Houston, TX

Based in Houston, TX, OmniCase manufactures high-quality protective cases, specializing in custom foam packaging solutions. They engineer durable foam inserts in-house, precisely tailored to safeguard valuable equipment for diverse commercial and industrial applications. With decades of experience, OmniCase provides robust, Made in USA protective packaging.

Hayward, CA

Based in Hayward, CA, PDCI Medical specializes in custom die-cut solutions, converting medical-grade polymer films, foils, and foams. The company provides engineered components for diverse markets, including medical packaging, automotive, electronic, and energy, delivering precise manufacturing.

Based in Lawrence, MA, Pack4 manufactures custom protective foam packaging, fabricating polyethylene and polypropylene foam. They design individually-tailored solutions for customer-specific parts and equipment. Utilizing state-of-the-art equipment, Pack4 offers quick-turn production and diverse materials for high-quality, cost-effective packaging.

Los Angeles, CA

Based in Los Angeles, CA, Packtodo designs, prints, and manufactures custom branded packaging solutions. They provide a range of products including custom boxes, bags, totes, and specialized inserts, such as Eva foam inserts, to ensure product safety and quality for various items.

PakFactory manufactures custom foam packaging inserts, providing die-cut and customizable solutions for maximum impact absorption. They safeguard valuable products with personalized, high-quality foam. The company also offers custom printed boxes and branded packaging, alongside strategic services such as packaging audits and supply chain optimization.

Platt Cases is a foam fabricator specializing in custom foam inserts using an in-house water-jet machine. The company provides precisely cut foam packaging solutions designed to protect various items. They also offer a range of protective cases, including foam-filled options, and custom product solutions.

North Canton, OH

Polymer Packaging is a manufacturer specializing in custom protective packaging solutions, including foam fabrication. They utilize various foam materials such as polyethylene, polyurethane, EPP, EPS, and XLPE. Capabilities include die-cutting, hot-wire cutting, and laminating, serving diverse industries like automotive, medical, electronics, and aerospace.

Pomona, CA

Based in Pomona, CA, Pomona Quality Foam, LLC fabricates custom foam packaging and components. They utilize sophisticated CNC technologies for precision cutting and laminating diverse foam types, including open and closed-cell. The company serves aerospace, government, furniture, and automotive industries, prioritizing quality and fast turnaround.

Fairfield, OH

Protective Packaging Solutions, based in Fairfield, OH, specializes in fabricating and manufacturing custom foam packaging. They utilize various foam materials for cushioning and padding, providing tailored protective solutions for industrial and commercial product safety during transit and storage.

Visalia, CA

Pregis specializes in innovative protective packaging solutions, including advanced foam technology. The company develops sustainable options like the EverTec™ cushioned shipping mailer, made with certified-circular polyethylene resins and designed to be curbside recyclable, solving tough business challenges for customers.

Escondido, CA

ProtexFoam, based in Escondido, CA, designs and manufactures custom foam inserts for various professional and industrial applications. They provide protective foam solutions for industrial hand tools, aerospace components, sales and marketing kits, and automotive parts, serving large B2B clients.

Clinton Township, MI

Based in Clinton Township, MI, Rapid Die Cut specializes in custom-cut foam inserts and packaging. They offer on-demand die cutting and digital manufacturing for prototypes and high-volume production. Utilizing various non-metallic materials, including contour foam, they provide custom solutions to protect products for diverse project needs.

Sherman, TX

Based in Sherman, TX, Royal Case Co. specializes in precision-engineered custom foam fabrication for maximum protection and organization. They provide wholesale cases with tailored foam inserts, offering solutions for diverse industries, including medical. The company also manufactures custom cases using injection molding, blow molding, and thermoforming.

San Antonio, TX

Based in San Antonio, TX, San Antonio Foam Fabricators specializes in custom foam and plastic fabrication. With over 40 years of experience, they provide die cutting services for various plastic materials, ideal for industrial and commercial applications, including protective foam packaging. They offer free quotes and efficient service.

Poway, CA

Based in Poway, CA, San Diego Crating & Packing manufactures custom foam packaging components. They provide basic foam sheets, foam lining for crates, custom contoured foam cuts, and die-cut foam inserts. Serving diverse B2B industries including Aerospace, Pharmaceutical, and Defense, they offer comprehensive protective packaging solutions.

Chesterfield, MO

Based in Chesterfield, MO, Crown Packaging Corp. specializes in expanded polystyrene (EPS) coolers, serving cold chain packaging and shipping needs. They provide custom foam packaging solutions tailored for businesses, complementing a wide array of other packaging products and comprehensive local support.

Danville, VA

Signode, based in Danville, VA, manufactures molded polyurethane foam packaging solutions, ideal for cushioning products in automotive, appliance, and medical industries. They also offer a comprehensive portfolio of end-of-line packaging products and systems, including strapping, wrapping, and automation equipment.

Houston, TX

Based in Houston, TX, Sterling Manufacturing offers custom-fabricated polyethylene foam sheets, rolls, and foam packaging services. With over 50 years of experience, the company designs and manufactures custom foam solutions for a wide array of industrial and commercial applications.

Brooklyn Park, MN

Based in Brooklyn Park, MN, Styrotech, Inc. manufactures and fabricates expanded polystyrene (EPS) foam. They specialize in protective packaging, custom OEM products, and diverse industrial applications. The company also produces various insulation solutions, including roof, general, and specialized foam for commercial clients.

Centerville, MN

Sunpack manufactures custom foam packaging solutions, specializing in die-cut foam inserts engineered to securely hold products of any size within boxes. They provide tailored foam additions to various packaging, ensuring optimal product protection and a secure fit for commercial and industrial applications.

Based in Hunt Valley, MD, Universal Foam Products specializes in providing Expanded Polystyrene (EPS) products. Operating nationally, the company leverages a network of over 100 shipping locations to supply a wide range of EPS foam solutions, including those utilized in diverse packaging applications for commercial and industrial clients.

Charleston, SC

Based in Charleston, SC, Ventek Solutions manufactures engineered shape molded foam components and protective packaging. The company also provides multi-material assembly solutions, addressing challenges in product protection, light-weighting, and insulation. With 10 facilities across North America, they serve diverse markets including construction, aerospace, military, and agriculture.

Irvine, CA

Based in Irvine, CA, Victory Foam, Inc. specializes in designing and producing custom foam packaging solutions for industry products. With over 30 years of experience, they provide custom foam for tool control, FOD prevention, and case inserts. Their ISO-9001:2015-certified facilities deliver expertly engineered retention and suspension packaging.

North Salt Lake, UT

Based in North Salt Lake, UT, Wasatch Container manufactures custom foam packaging solutions. They specialize in anti-static foam designs for electronic parts and equipment, dissipating electrostatic charges. The company also produces a range of other packaging, including boxes, displays, crates, and protective cases, collaborating on ideal solutions.

Sunnyvale, CA

Based in Sunnyvale, CA, WeCutFoam specializes in custom foam packaging solutions, offering foam inserts, cushioning, and liners for boxes, crates, and cases. They provide foam cutting, machining, and prototyping services using materials like PE, XLPE, EVA, EPS, XPS, and EPP for various industrial and commercial applications.

Elkhart, IN

Worldwide Foam manufactures and supplies a wide range of closed-cell, cross-linked polyethylene foam from seven strategic US locations. They offer high-quality foam materials with efficient one-day lead times. Their products are ideal for diverse industrial and commercial packaging applications, providing essential protective solutions.

North Little Rock, AR

Creative Foam Products is a custom foam manufacturer specializing in expanded polystyrene, expanded polypropylene, and graphite polystyrene. The company provides high-quality foam products for businesses, focusing on consistent delivery and meeting customer needs.

Clawson, MI

Based in Clawson, MI, Foam For You specializes in manufacturing custom foam packaging. They design and produce tailored foam inserts to protect fragile equipment during shipping, warehousing, or general handling. The company also offers wedge foam tiles for sound control and custom foam cushions for furniture and mattresses.

Bucyrus, OH

Ohio Foam Corporation specializes in the manufacturing and conversion of flexible foam products for various applications. They serve diverse markets including automotive, heavy truck, agriculture, marine, medical, military, furniture, and bedding industries. The company collaborates with businesses, providing cost-effective foam solutions from initial idea to completion.

Riverside, CA

Based in Riverside, CA, Project 14 specializes in custom foam packaging and custom crates. The company provides tailored packaging solutions for industrial and commercial customers throughout Southern California, including Los Angeles, Orange County, and San Diego.

Smithfield, RI

Based in Smithfield, RI, Branch River manufactures packaging foam engineered to protect shipments. Their foam products provide insulation for temperature-sensitive items, ensuring product integrity during transport. They deliver custom foam solutions for diverse commercial and industrial clients.

Garland, TX

Based in Garland, Texas, Guardian Packaging specializes in high-precision foam cutting and integrated packaging systems. The company manufactures custom foam solutions designed for various commercial and industrial applications, ensuring secure and protective packaging for diverse products.

Fort Worth, TX

Based in Fort Worth, TX, Conner Packaging offers industrial packaging solutions with over 40 years of experience. The company specializes in foam packaging, designing and manufacturing custom solutions for a range of industrial applications. They provide comprehensive expertise in developing protective packaging to meet specific client needs.

Fenton, MI

Based in Fenton, MI, Creative Foam is a manufacturer specializing in engineered foam and non-woven material solutions. The company provides custom fabrication, die-cutting, lamination, and assembly services for various applications, including protective foam packaging, automotive components, medical devices, and industrial products.

Tustin, CA

Based in Tustin, CA, Custom Boxes and Packaging manufactures custom packaging solutions. They provide diverse packaging options, including foam inserts tailored for product protection and cushioning during shipment. The company serves commercial clients by addressing their specific custom box and packaging requirements, ensuring safe and secure transit.

Elkhart, IN

Based in Elkhart, IN, EFP, LLC. manufactures engineered protective packaging and cold chain solutions. The company utilizes a broad range of materials and provides packaging design services for protection and distribution challenges. EFP also offers packaging supply chain services and sustainable solutions.

Fe Springs, CA

E-Z Flow Foam Systems manufactures premium polyurethane foam solutions for diverse industrial applications. They specialize in creating molded foam products, including custom molds and mold bases for packaging. Their product offerings extend to flotation foam, thermal insulation, structural foam, and materials for stage and movie props.

San Diego, CA

Based in San Diego, CA, Flexy Foam is a family-owned manufacturer producing diverse foam projects for industrial applications, including foam packaging. They operate from three facilities across the western U.S., including Chino, CA, and Phoenix, AZ, specializing in custom foam solutions.

Macomb, MI

Based in Macomb, MI, Foam Factory, Inc. manufactures and custom-cuts a wide selection of foam products. They specialize in providing packaging materials and custom packaging foam, utilizing their cutting equipment for 2D shapes. The company serves commercial clients, also offering acoustical foam, cushions, and insulation.

Council Bluffs, IA

Future Foam specializes in manufacturing and fabricating advanced engineered foam, foam buns, and blocks. They provide pouring, fabrication, and cushioning capabilities for diverse applications. Serving sectors like marine, medical, furniture, and bedding, the company offers custom foam solutions.

Dallas, TX

Heubach Corporation, based in Dallas, TX, manufactures custom foam products and offers diverse foam fabrication services. Their capabilities include CNC and water jet cutting for various packaging product applications. Operating from multiple US facilities, Heubach provides comprehensive manufacturing and material solutions.

Carol Stream, IL

Kaiser Manufacturing specializes in creating fully customized, rigid foam inserts for tool control, kitting, and protective packaging. Utilizing 3D scanning technology, they produce Kaizen Shadow Foam® inserts that organize and protect tools, components, and investments. Their solutions support lean manufacturing and eliminate foreign object debris.

Brunswick, OH

Based in Brunswick, OH, M-Line manufactures custom foam packaging solutions. They provide custom-cut foam inserts, sheeting, and pouches, along with full-service design and engineering capabilities. Serving businesses in Ohio and Pennsylvania, the company specializes in protecting products with tailored foam packaging.

Huntington Beach, CA

Marko Foam Products manufactures custom foam packaging and solutions for diverse industries, operating since 1961. They provide insulated containers, corner blocks, and edge protectors. Specializing in medical and beverage packaging, the company offers robust protection for sensitive items from facilities in California and Utah.

Barberton, OH

Based in Barberton, OH, Merryweather Foam manufactures custom foam products, offering over 1,000 foam materials and 35,000 custom products. They utilize advanced manufacturing capabilities including CNC cutting, die cutting, and adhesive lamination to serve diverse industries like aerospace, automotive, medical, and general industrial applications.

Hartford, CT

Based in Hartford, CT, New England Foam Products manufactures and supplies custom open-cell and closed-cell foam. They utilize materials like polyurethane, polyethylene, and polyester for specialized foam products. Serving various industrial applications, the company provides tailored foam solutions, including protective packaging and components for commercial clients.

Zebulon, NC

Based in Zebulon, NC, Nomaco manufactures polyethylene, polypropylene, and hybrid foams. They produce these lightweight foams in various forms, including rolls, tubes, sheets, planks, and unique profiles, catering to diverse industrial applications.

Premier Packaging offers comprehensive packaging solutions, including void fill systems like paper, inflatable packaging, and foam-in-place options. The company provides packaging products, equipment, and design services to help businesses protect their products during shipping. They maintain strategic locations across the United States and Mexico to support client needs.

Hickory, NC

Based in Hickory, NC, PTI, LLC is an ISO 9001:2015 certified foam manufacturer specializing in custom-engineered foam extrusions. With 40 years of expertise, they produce polyethylene, polypropylene, and other engineered foam profiles in truckload quantities. Their foams provide excellent shock absorption and sound dampening for packaging applications.

Reilly Foam Corporation fabricates quality foam products, specializing in diverse foam solutions and services for over 40 years. The company provides customized foam materials designed for various industrial and commercial applications, including protective packaging, cushioning, and insulation. They serve businesses seeking tailored foam product solutions.

Sealed Air manufactures protective packaging solutions, including foam packaging products designed to safeguard valuable items during storage, transit, and shipping. The company provides innovative solutions that enhance product protection, improve operational efficiency, and support sustainability initiatives for various commercial and industrial clients.

Redlands, CA

Based in Redlands, CA, Superior Packaging Solutions provides custom and stock packaging for Southern California businesses. The company specializes in designing and manufacturing protective packaging, including custom foam inserts, foam end caps, and cushioning. They also offer foam blocks, sheets, and rolls.

Sur-Seal specializes in custom manufacturing of engineered components and materials, providing foam die-cut solutions for optimal product shipping. They produce precise die-cut, molded, and formed products to meet diverse manufacturing needs. Certified AS9100- and ISO9001-compliant, Sur-Seal is a Preferred Converter for 3M.

Buffalo, NY

Thermal Foams, Inc. manufactures protective foam packaging solutions utilizing its lightweight Tru-R material. They specialize in designing and shaping custom foam for precision fit, providing thermal properties, cushioning, and strength. Serving industrial and commercial clients, the company ensures optimal product protection for various packaging applications.

Evansville, IN

Based in Evansville, IN, Thrust Industries specializes in custom die-cut products, including foam for packaging and shipment. They offer fast-turn prototyping and production services, adhering to ISO 9001:2015 quality standards. The company provides expert material guidance and delivers custom die-cut parts efficiently.

Hayward, CA

TransPak Inc. provides advanced foam packaging solutions, custom industrial crating, and export packaging services. They offer comprehensive design, testing, and logistics, serving critical industries such as semiconductors, data centers, aerospace, automotive, medical, and defense.

Based in Newburyport, MA, UFP MedTech develops and manufactures medical devices and sterile packaging solutions. They specialize in using closed-cell and open-cell medical-grade foams for both components and packaging. The company offers full-service support from design and development through manufacturing, focusing on single-use and single-patient devices.

Grand Rapids, MI

Based in Grand Rapids, MI, UFP Packaging designs and manufactures custom foam components, from simple pads to multi-stage cushioning systems. This full-service industrial packaging company also provides wooden pallets, custom crates, skids, and cut lumber, serving diverse industries and customers worldwide.

Clearwater, FL

Based in Clearwater, FL, We Make Foam manufactures custom foam packaging solutions. They produce molded EPS foam, sheets, blocks, and packing peanuts from PE, PU, XLPE, and EPS. Capabilities include CAD design, CNC routing, hot wire cutting, and molding, serving diverse industries with specialized packaging.

Oklahoma City, OK

Based in Oklahoma City, OK, WIC Packaging specializes in designing and fabricating custom foam packaging solutions, including cushioning, components, and consumables. The company offers engineering design, prototyping, and comprehensive fulfillment services, such as kitting and crating. WIC Packaging serves diverse industries like medical, aerospace, and telecommunications.

Madison, WI

Based in Madison, WI, Wisconsin Foam Products fabricates flexible foam solutions, including anti-static and ESD packaging foam. The company provides finished foam products, components, assemblies, and packaging to OEM customers across various industries. They maintain a diverse inventory of open and closed cell foam alternatives.

Carpenter Co. is a vertically integrated manufacturer of polyurethane foams, offering eco-friendly foam packaging solutions. These protective packaging materials are made from durable, safe, and clean components, designed to be recyclable and free of CFC & HCFC. The company operates globally with over 60 production locations.

The Foam Factory specializes in manufacturing anti-static foam products in the USA. They provide cushioning solutions for sensitive electronics, including circuit boards and computer chips, serving various industrial packaging needs.

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How to Choose a Company

  • Verify the supplier's specific fabrication capabilities; do they offer precision die-cutting for intricate internal geometries or robust waterjet cutting for thicker, high-density foams, crucial for your product's snug fit and protection?
  • For products requiring certified transit protection, inquire about the manufacturer's experience with ISTA testing protocols (e.g., 1A, 3A, 6A) or their ability to collaborate with accredited labs to ensure your foam packaging design meets specific shipping performance standards.
  • Assess their material expertise beyond generic foam grades; specifically, confirm if they routinely work with specialized materials like anti-static (ESD) foam, Plastazote, or high-performance expanded polypropylene (EPP) for applications with unique thermal, static, or cushioning demands.
  • Beware of suppliers who provide quotes without thoroughly discussing tooling costs (e.g., steel rule dies for die-cutting, mold costs for EPP/EPS) and lead times; these can be significant upfront investments that disproportionately affect project budgets for custom foam inserts.

Frequently Asked Questions

How do I ensure my foam packaging protects against electrostatic discharge (ESD) for sensitive electronics?

To protect sensitive electronics, you must specify anti-static or conductive foam materials, not just standard foams. Look for suppliers who offer specialized polyethylene or polyurethane foams with documented surface resistivity ranges (e.g., 10^4 to 10^9 ohms/sq for static dissipative). Always request material data sheets confirming compliance with relevant ESD standards like MIL-PRF-81705D Type II for static dissipative or Type I for conductive properties, and clearly communicate your product's ESD vulnerability.

What's the critical difference between using molded foam versus fabricated (die-cut/waterjet) foam for my product?

Molded foam, typically EPP or EPS, involves injecting foam beads into a mold and is ideal for high-volume production, complex geometries, and superior part-to-part consistency once tooling is created. It often offers lower unit costs at scale. Fabricated foam, made by die-cutting, waterjet cutting, or routing large foam blocks (e.g., PE, PU), is better suited for lower volumes, rapid prototyping, and designs that may require frequent adjustments. While tooling for fabricated foam (like steel rule dies) is generally less expensive, individual piece costs for intricate designs can be higher due to material yield and labor.

What material properties should I prioritize when specifying foam packaging for heavy, fragile items?

For heavy, fragile items, prioritize foams with excellent energy absorption and high compression set resistance. Energy absorption, often correlated with foam density (e.g., higher density polyethylene or polyurethane), determines how effectively the foam dissipates impact forces to protect your item. Compression set resistance is crucial; it refers to the foam's ability to recover its original thickness after repeated compression, ensuring long-term cushioning performance. Additionally, consider the foam's resiliency to absorb multiple impacts without losing protective integrity, and always provide your product's weight, dimensions, and fragility G-force limit to the manufacturer for precise material selection.

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