Foam Fabrication Capabilities


Foam Fabrication

New England Foam has many fabricating techniques.  From the capability to make large sheets and blocks to the capability to cut shapes and produce small delicate foam parts.

We use large horizontal and vertical saws to sheet and block down buns and planks of foam.  This is the starting point in the fabrication process, weather we are processing foam sheets for a customer or cutting multiple nested parts from a sheet or block.

Our CNC Vertical Contour Cutter can precisely create unique shapes that are cut quickly and efficiently.  With a CNC contour cutter, we can cut shapes that are much thicker than parts that would otherwise be die cut or waterjet cut.

The Die Cutting technique is popular for thinner foam parts that are more price sensitive and typically higher volume pieces.  New England Foam has large die presses that allow us the capability to utilize large multiple up die tools that create many parts with one die cut hit to maximize efficiency and the yield of the material.

Additionally, we also have foam CNC machining capabilities.  CNC machining is usually best suited for dense closed cell foam with smaller volumes.

We have the ability to fabricate convoluted or egg crate polyurethane foam.  This is a popular choice for case lid inserts as well as a quick and easy universal protective packaging option.

New England Foam has several different bonding techniques

PSA, Pressure Sensitive Adhesive, is a convenient way to create a 100 percent bond between two surfaces.  It is also an easy way for the customer to bond the foam to their product in house without set up of a glue system.

Additionally, we offer spray glue and cold glue which are great when you need a bonded joint to remain soft, flexible and pliable.  Perfect for medical soft goods applications!

Lastly, we can use hot melt glue rollers and glue guns for bonding foam to foam as well as foam to other materials like wood, corrugated, plastic and nylon.

Foam Product Development Services

  • Computer Aided Design (CAD)
  • Contract Manufacturing
  • Custom Tooling
  • Drop Shipping
  • Long and Short Runs
  • Product Design
  • Product Development
  • Product Engineering

Foam Cutting

  • Compression
  • Computer Numerically Controlled (CNC)
  • Contour
  • Convolutiing
  • Dado
  • Hot Wire
  • Skiving
  • Slitting
  • Splitting
  • Die Cutting
  • Drilling

Foam Assembly

  • Bonding
  • Flocking
  • Hot Melt Glue Guns and Rollers
  • Lamination
  • Plastic Corrugated to Foam
  • Pressure Sensitive Adhesives (PSA)
  • Sewing
  • Wood-to-Foam
  • Spray Glue

From Design Concept


To Prototype


To Production Run

  • M-Series
  • Fecken-Kirfel
  • Gerber
  • cutting