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Manufacturing Capabilities
Experts in foam fabrication and custom foam manufacturing
At Kewell Converters, we’re specialists in bespoke foam manufacturing, delivering precision-engineered foam components that support critical manufacturing and distribution processes. For over 50 years, we’ve partnered with procurement professionals, engineers, and quality managers across industries including aerospace, medical, defence, automotive, and industrial manufacturing. Whether you’re sourcing CNC-routed foam inserts, high-performance seals, or custom gaskets, our UK-based team provides expert support from concept to completion.
We design and fabricate each solution with your application and performance goals in mind. Our team works closely with you to ensure every component integrates seamlessly into your supply chain and meets your technical, safety, and compliance requirements.
Precision-driven design and technical foam expertise
Our design process is focused on the final use of each foam component. By understanding the environment, function, and regulatory considerations, we can propose materials and configurations that deliver long-lasting performance. Whether you need to insulate wiring on an aircraft, protect fragile instruments in custom transit packaging, or present consumer goods with high-end appeal, our team ensures that every product we supply is fit for purpose.
We draw on deep expertise in technical and performance foams, working with a wide variety of open-cell and closed-cell materials. This allows us to solve complex challenges across engineering, display, hygiene, and construction sectors. Our consultative approach ensures you’re not only getting a product — you’re getting a reliable solution backed by decades of foam innovation.
CNC foam machining and advanced fabrication capabilities
Our UK manufacturing facility is equipped with advanced CNC routing and multi-axis milling machines that deliver tight-tolerance foam components with exceptional repeatability. Using both traditional and state-of-the-art techniques, we manufacture everything from small precision parts to large-scale assemblies. Our capabilities include 2D and 3D CNC routing, die-cutting, laminating, bonding, and thermoforming. Whether you’re developing a prototype or scaling up for full production, our flexible approach ensures lead times are minimised and quality is never compromised.
Custom foam products manufactured in-house
We produce a wide range of custom foam parts including sheets, rolls, blocks, and strips, as well as more specialist items such as acoustic panels, filter foams, and scaffold protectors. Our offering also includes case inserts, presentation kits, medical-grade foams, seals, gaskets, and thermoformed mouldings. All products are manufactured to meet strict quality standards, and we can support both one-off projects and large, repeat production runs.
Zotefoams accredited fabricator
As an approved UK fabricator and distributor of Zotefoams, we provide access to high-performance materials such as Plastazote®, Evazote®, Supazote®, and Zotek® foams. These closed-cell foams are renowned for their lightweight strength, durability, and chemical resistance, making them ideal for applications where hygiene, safety, and compliance are non-negotiable. We supply a full range of grades, densities, and thicknesses to suit your exact specifications.
Trusted by industry leaders across the UK
We’re proud to serve some of the UK’s most respected manufacturers across sectors such as defence, healthcare, transport, energy, and engineering. Our clients trust us to deliver foam solutions that are consistent, compliant, and competitively manufactured. Whether you’re looking to solve a technical challenge, streamline a production process, or enhance product protection, we’re ready to help.
Contact our manufacturing team today to discuss your foam project, or explore our full range of materials and capabilities.
