• Phone Polyformes 01525 852444
  • Email Polyformes sales@polyformes.co.uk


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Our Foam Manufacturing Processes

Closed cell expanded polyethylene foam is an amazing material. It surprises many people when they find out about the never-ending range of products that can be made from it. Its versatility, range of densities and colours, as well as anti-static, conductive and flame retardant options, make it a choice for use in the aerospace, automotive, defence and security markets. Many other markets enjoy the protection, security and enhancement it can offer its own products.

To make all of the amazing parts that you want, the material needs to be engineered. This is what Polyformes do very well. Our core business is working closed cell flexible polyethylene foam and providing solutions to our large client base. That focus enables us to concentrate on buying, making or adapting machinery that will shape the foam in the way you want it to be. This is where our many years of experience lies and it all takes place under our own very large roof!

We take on many technical challenges that others do not entertain. As foam innovators, technical foam engineers and foam designers, we can provide you foam solutions that satisfies your industry and market.

We, in fact, utilise and develop whatever machinery, parts or products are available in order to achieve what you require. We deliver your foam solutions in the most cost effective and efficient way.

If you have some ideas or would like to develop an existing product, make contact and between us lets see where it goes.

If we cannot do what you are looking to achieve we will tell you! We do not like wasting your time.

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Speak to a member of our team today to discuss your specific requirements

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Specialist Foam Processes

For more than four decades, at Polyformes Ltd, we have been working with Polyethylene foam materials. We utilise a number of different foam processes designed to mould and form foam for number of different applications.

Whether you're looking to have foam material cut to a specific size, engraved to create a numbered effect or printed to promote your brand, we have the solution for you and your clients. Some of our most frequently used processes include CNC routing & machining, moulding & forming, waterjet cutting and more.

CNC Routing & Machining

Using our specialist foam machining process, we are able to achieve high quality, high volume output of both two and three dimensional PE foam parts. CNC routing & machining is fully operated digitally by computer software. Each head has a seven-tool auto-changer allowing for greater machine speeds and also allowing for a number of specialist cutters to be employed on individual parts.

Moulding & Forming

At Polyformes, we work closely with our clients in order to provide a foam solution to their brief and final product criteria. Intricate and well-defined moulded foam parts can be utilised across a number of different industries particularly aerospace and defence industries where accuracy is vital.

Waterjet Cutting Foam

Unlike with other foam cutting processes, waterjet cutting is specially programmed to cut the exact shape required of the finished component meaning that right-angled corners, sharp hair-pin bends and curves prove no problem. Over the years we have used waterjet cutting for a number of industries including industrial, aeronautical and promotional.

Foam Printing

At Polyformes, we utilised our very own unique patented 4 colour printing for foam. We have developed and patented our technique the brings alive and enhances any product or packaging with colour. The quality of print is exceptional and extremely hard wearing.

In the past our clients have used foam printing for exercise mats, mouse mats, tool and product identification as well as much more. For more information on any of our foam process, please do not hesitate to get in touch with us today and we will be more than happy to help.

Bespoke Flight Case Making

In addition to manufacturing a number of different foam materials for our clients across the UK & Europe, we also manufacture bespoke flight cases and road trunks at our factory. Our flight cases are designed unique for your business or clients. We service all industries including medical product manufacturers, hospitals, water and utility companies, the electronics market as well as music and broadcast industries.