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Aerospace & Aviation
Lightweight, fire-retardant, high-performance foams for aviation and aerospace applications
With over 50 years of dedicated foam conversion expertise, Kewell Converters is a trusted partner for aerospace and aviation manufacturers seeking high-performance, bespoke foam components. We specialise in solving complex challenges for the most demanding environments—where weight savings, thermal efficiency, and fire safety aren’t just preferences but requirements.
From civil and commercial aviation to defence and military applications, we design and manufacture custom foam parts engineered for precision, durability, and compliance with strict industry standards. Our specialist knowledge of high-quality foam materials and their performance characteristics makes us the ideal partner for aerospace procurement and engineering teams seeking full-service foam fabrication support.
Why leading aerospace procurement teams choose Kewell Converters
- Unmatched foam expertise – with five decades of experience working exclusively with foam, our engineering team understands the tolerances, material behaviour, and design optimisation techniques that produce the best results
- Zotefoams specialists – we have extensive experience working with ZOTEK® and PLASTAZOTE® branded foams from Zotefoams, known for their lightweight, energy-absorbing and fire-retardant properties
- Built-in CAD design & engineering – every aerospace project includes full CAD support from our in-house team, ensuring design optimisation from the start
- One-stop foam solution – from material selection and design through to production and supplier management, we simplify your supply chain by delivering complete, engineered foam solutions
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Bespoke foam components for aerospace and defence applications
We provide high-quality foam parts for a wide range of aerospace components.
Our high-quality foam materials are selected for their:
- Low density and weight
- Excellent thermal insulation and acoustic damping
- High tensile and tear strength
- Resistance to flame, smoke, and toxic gas emission
- Compatibility with aerospace adhesives and lamination
Need foam parts that meet rigorous specifications? Let’s talk.
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Cabin interiors
Foam inserts and trim made from PLASTAZOTE® for seating, panels, and comfort pads
Thermal and acoustic insulation
Engineered parts using ZOTEK® F foams for airframes, ducts, and linings
Protective foam
Crash pads, headrests, and lightweight foam shapes for safety and impact absorption
Military-grade packaging
Durable foam inserts and protective packaging with precise tolerances
Galley and cargo areas
Foam components that withstand chemicals, vibrations, and fluctuating temperatures
Meeting industry standards with technical precision
We understand that aerospace and defence sectors are tightly regulated, specification-led industries. That’s why Kewell Converters works closely with procurement and engineering teams to ensure compliance with all relevant aerospace standards, including fire resistance, smoke toxicity, thermal efficiency, and mechanical strength.
We don’t just cut foam—we solve problems. By leveraging our in-house engineering team and advanced foam conversion capabilities, we help organisations reduce weight, increase efficiency, and ensure product consistency across every production run.
Our factory in Kent is fully equipped to laminate, die-cut, rout, CNC machine, weld, and fabricate foam parts with repeatable precision. Whether you need a prototype or a full production run, you can expect accuracy, speed, and reliability.
Trusted by the aerospace supply chain for over 50 years
As one of the UK’s few independent foam converters working solely with foam, Kewell Converters offers a depth of specialist knowledge you won’t find elsewhere. We focus on delivering the highest-quality bespoke foam solutions for customers who value precision and performance.
From initial concept to finished part, we support:
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- Aerospace procurement managers
- Military and defence contractors
- Production and operations teams
- Aerospace engineers and product developers
Contact us today to discuss your aerospace foam requirements
Whether you need custom foam inserts, lightweight energy-absorbing parts, or complete foam assemblies managed and delivered to spec, Kewell Converters is ready to support your next project.
FAQs
We specialise in high-performance foams like ZOTEK® F and PLASTAZOTE®, known for being lightweight, fire-retardant, and compliant with aerospace standards.
Yes. We work with foams that meet fire, smoke, and toxicity (FST) regulations and supply parts engineered to meet strict aerospace specifications.
Absolutely. We supply bespoke foam solutions for both civil aviation and military sectors, including cabin interiors, thermal insulation, and protective packaging.
Yes, we support everything from single prototypes to full-scale production, all backed by in-house CAD design and engineering expertise.
Our facility uses advanced CNC routing, die-cutting, and lamination processes—combined with full CAD support—to ensure every part meets exact specifications.
