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Buoyancy & Floatation
High-performance buoyancy & flotation foam solutions
At Kewell Converters, we specialise in engineered foam solutions that deliver critical buoyancy, flotation, and protection in sectors where safety, precision, and performance are paramount. With over 50 years of exclusive expertise in foam conversion and foam fabrication, we design and manufacture bespoke foam parts for the marine, defence, aerospace and industrial applications; from foam inserts for specialist life-saving equipment to complex buoyancy blocks for modular structures, Kewell Converters is the trusted foam fabricator for projects where failure isn’t an option.
Engineered for water, built for performance
Our custom foam flotation and buoyancy components are designed for environments where moisture, impact, and environmental resistance are critical. We fabricate using closed-cell, high-quality foam materials, including Zotefoams’ Plastazote, Evazote, and Zotek ranges—ensuring low water absorption, minimal permeability, and long-term durability even in saltwater and UV-exposed environments.
Applications include:
- Lifejackets and buoyancy aids (meeting EN393 and SOLAS standards)
- MOB systems, rescue stretchers and cradles
- Buoys and floats – cylindrical, anchor pendant, navigation and mooring
- Foam fenders and impact protection for RIBs and marine structures
- Tubular hose floats, curtain booms, and oil containment systems
- Diving equipment cases, instrument panels, and navigation enclosures
- Hydrotherapy and disability aids for aquatic use
The foam advantage: why closed-cell foam wins at sea
Our specialised foam solutions outperform traditional materials like polystyrene and inflatable systems.
This makes it ideal for high-performance marine equipment, defence flotation systems, and aerospace rescue components.
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Doesn’t absorb water, even if punctured
Is resistant to algae, mould, and UV degradation
Maintains buoyancy, shape, and cushioning under stress
Is lightweight yet structurally reliable
Offers low maintenance, high durability, and easy fabrication into custom shapes
Beyond materials: full-service foam engineering
We don’t just sell foam—we solve problems. With Kewell Converters, you get more than material supply:
- Full CAD design and prototyping as standard
- Material selection tailored to application needs (weight, chemical resistance, thermal performance)
- CNC machining, lamination, waterjet and die-cutting for precision manufacturing
- Supplier liaison and full supply chain management for turnkey project delivery
- On-time delivery of ready-to-install parts, no additional processing needed
We’re increasingly managing the complete lifecycle of a foam component—from sourcing to delivery—allowing your team to focus on the bigger picture without the complexity of multiple vendors.
Proven experience: a case study in hydrotherapy float aids
Kewell Converters is proud to have created an award-winning swimming pool float aid for disabled children—helping users gain mobility, safety and independence in hydrotherapy sessions. Designed in partnership with healthcare professionals, our bespoke foam flotation devices include collars, neck supports, and body aids fabricated from Zotefoams’ Plastazote, chosen for its water resistance, hygienic properties, and comfort.
These solutions are easy to clean, adjustable for various needs, and suitable for use in both pools and baths. With additional experience supplying MRI- and X-ray-lucent foam components, orthotic supports, and protective medical aids, we bring the same level of expertise and care to every marine and flotation product we manufacture.
Let's talk about your project
If you need a foam flotation or buoyancy solution that delivers certainty, safety and durability in the field, talk to Kewell Converters. We’ll help you develop a custom foam part that’s as precise and high-performing as the systems it supports.
FAQs
We use high-quality closed-cell foams like Plastazote, Evazote, and Zotek from Zotefoams, chosen for their water resistance, durability, and structural integrity in demanding environments.
Yes. Our closed-cell foam is designed to resist saltwater corrosion, UV degradation, and environmental wear, making it ideal for marine and outdoor applications.
Yes, our flotation products can be made to meet standards like EN393 and SOLAS, ensuring they perform reliably in life-critical applications.
You can request a quote or book a consultation directly through our website. Our team is ready to assist from initial concept through to delivery.
