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Bespoke Foam Solutions
Designed for demanding sectors
Tailored, high-performance foam parts and assemblies engineered for defence, aerospace, and industrial environments
At Kewell Converters, we don’t just shape foam—we engineer solutions. With over 50 years of specialist expertise in foam conversion, we design and manufacture complex, bespoke foam parts for critical applications where reliability, durability, and precision are non-negotiable.
Our customers include some of the most advanced organisations operating in the military, defence, aerospace, and industrial sectors—each with their own unique challenges and compliance requirements. Whether you’re sourcing custom foam packaging, specialised foam inserts, or fully integrated foam components, we provide high-quality, tailored solutions backed by engineering expertise and a proven track record.
A turnkey approach to foam project delivery
What sets Kewell Converters apart isn’t just what we make—it’s how we deliver.
We manage more of the supply chain so you don’t have to. Increasingly, our clients are trusting us to source materials, coordinate with third-party suppliers, and oversee complete production workflows. This integrated, end-to-end approach reduces your supplier count, shortens timelines, and gives your team one reliable point of contact from concept to completion.
Whether we’re producing bespoke military foam inserts for defence case systems, aerospace-grade foam panels, or complex assemblies for industrial automation, we treat every job with the same focus on quality, compliance and delivery.
Thanks so much for your time earlier, we really appreciate you coming all this way to see us. We were all very impressed by the quality of your foam and hope to work with you more in the future
Engineering-led foam fabrication
Unlike generalist converters, Kewell Converters operates with a dedicated in-house engineering team. Projects benefits from full CAD design support, feasibility reviews and design-for-manufacture (DFM) input—ensuring every component we produce is both functionally optimised and cost-efficient.
From the moment you brief us, we collaborate closely with you to understand not just the product requirement, but the broader application. That’s how we turn material selection and manufacturing decisions into customer benefits: lighter parts, better protection, improved tolerance control, or simpler installation—whatever matters most to you.
And we’re utilising AI to revolutionise manufacturing—enhancing precision, accelerating innovation, and delivering superior products and services tailored to meet the evolving needs of our customers.
Our capabilities
We’re fully equipped to work with a wide variety of foam materials and foam grades and we understand their technical boundaries—allowing us to recommend the right material for your application, from lightweight closed-cell foams to high-density specialty foams with thermal, chemical or impact resistance.
Our Machine Capabilities
Precision-cut foam parts, panels, gaskets, seals, and inserts
CNC profiling and multi-axis routing of speciality foams
Fabrication using branded foams such as Plastazote®, Evazote®, and Zotek®
Multi-layer foam assemblies and component integration
Advanced thermoforming for complex geometries and enclosures
Prototyping and production support for custom foam solutions
Quality built in. Expertise you can trust.
Our commitment to quality is non-negotiable. With ISO-certified processes and a dedicated in-house quality assurance specialist, every part we produce is inspected and tested to meet strict standards and sector-specific tolerances.
With more than five decades of knowledge working exclusively in foam, our team understands the nuances of foam fabrication better than anyone in the UK. That expertise means fewer errors, faster turnaround, and better results—because we get it right first time.
Trusted by procurement, valued by engineers
Procurement teams value us for our consistency, communication, and ability to simplify complex supply chains. Quality managers know we build to spec and stand by our work. And engineers trust us to help them design and deliver foam components that perform under pressure—in the field, in the air, or on the factory floor.
Explore real-world solutions
Want to see what our bespoke approach looks like in action? Our case studies demonstrate how we’ve helped leading organisations develop, test, and deliver high-performance foam solutions that stand up to the toughest operational demands.
Our team is here to understand your requirements, share advice, and help bring your project to life.
Explore our case studies
Contact us today to discuss your bespoke foam solution.
Our team is here to understand your requirements, share advice, and help bring your project to life.
