Manufacturing Capabilities
Custom Foam & Fiber, Engineered for Performance
At Penn Foam, we don’t just supply cut foam parts; we actually manufacture the flexible polyurethane foam and polyester fiber in-house, giving us unparalleled control over consistency, quality, and performance. This integrated approach means we deliver exactly what a wide range of industries need, when they need it, and precisely to their specifications.
Flexible Polyurethane Manufacturing
We manufacture high-quality polyurethane foam in a variety of densities and firmness levels, tailored for use in furniture, packaging, and other applications.
Polyester Fiber Manufacturing
Our in-house fiber production allows us to create durable, uniform polyester fiber materials that perform consistently across commercial and OEM product lines.
Consistent Output & Fast Turnaround
With complete control over our manufacturing processes, we’re able to maintain strict quality standards and deliver reliable lead times for projects of any size.
B2B Focused
We work exclusively with manufacturers, fabricators, and commercial clients—providing scalable material solutions designed to meet the demands of production environments.
Fabrication Capabilities
Tailored to Fit Your Product. Every Time.
We use state-of-the-art fabricating equipment, technologies, and practices to transform raw block foam and roll fiber into precision-engineered foam and fiber solutions. This exacting approach ensures you receive consistent, high-quality parts and assemblies that seamlessly integrate into your product manufacturing.
Need Custom Foam Fabrication?
Reach out today to get expert guidance and a tailored solution.
Die Cutting & CNC Contour Cutting Lines
Our precision foam cutting technologies include computer controlled multi-axis CNC contour cutting machines, high-speed, high-volume die-cutting presses, bevelers, convoluters, and more — to produce precise, clean, repeatable foam shapes to meet exacting design specifications.
Skiving, Slitting & Sheeting
Our equipment allows us to adjust thickness, length, and form with high accuracy, making it easy to adapt foam and fiber materials for a wide range of applications.
Adhesive Application & Lamination
We use robotic glue stations, roll compression lamination lines, and precision spray application system to make sophisticated multi-layer, variable depth packaging inserts, specialty case solutions, fiber wrapped cushions, variable density foam cushions and more.
Engineering & Design Support
Our team collaborates with yours to refine concepts, solve design challenges, and produce production-ready components that integrate seamlessly into your product line.
