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Reticulated Filter Foam
Precision-engineered foam for filtration, ventilation and specialist protective applications
At Kewell Converters, we manufacture and supply high-quality reticulated foam products to the military, defence, aerospace and high-end industrial sectors. With over 50 years of foam conversion expertise, we’re one of the UK’s longest-established independent foam fabricator—specialising in bespoke foam solutions, custom foam parts, and complex foam assemblies that meet the most demanding performance standards.
What is reticulated foam?
Reticulated foam—often called reticulated filter foam—is a type of open-cell polyurethane foam that’s been processed to remove cell membranes, leaving a skeletal structure of interconnected strands. The result is a highly porous, breathable, and low-density material ideal for filtration, airflow, drainage and cushioning applications where controlled fluid or air flow is critical.
Kewell Converters works with a wide range of reticulated foam materials, including branded foams from trusted manufacturers like Zotefoams. Available in multiple grades and pore sizes, our reticulated foam can be tailored to your exact application—whether you need a precise flow rate, particle filtration level, cushioning response, or all of the above.
Key features of reticulated foam
Our reticulated foam is chosen for its technical versatility and performance benefits:
- Open-cell structure for controlled air and fluid flow
- Excellent drainage with minimal water retention
- Rapid drying properties, ideal for outdoor, marine or hygiene-critical environments
- High porosity available in various pore sizes (PPI grades)
- Customisable formats, from blocks and sheets to precision-cut foam parts, gaskets, inserts and shapes
- Durability and resistance to mild chemicals, cleaning agents and wear
Industry applications
Kewell Converters supplies reticulated foam components across multiple sectors, with particular expertise in demanding, high-stakes environments.
Because reticulated foam can be precision-graded, shaped and cut, it’s highly effective as a custom-engineered component in complex systems. Whether you need to regulate airflow, control particulates, or protect sensitive equipment—Kewell Converters can help you design and produce the right foam solution.
Military and defence
Protective ventilation foam, filtration blocks, foam inserts for ruggedised field equipment
Aerospace
Lightweight ventilation solutions, fuel cell filtration, sound-dampening foam
The Kewell Converters difference
As a foam converter exclusively focused on engineered foam solutions, we offer a large depth of expertise in foam materials, foam fabrication and foam design.
- Full CAD support and design for manufacture (DfM) included with every project
- End-to-end project management, including sourcing, prototyping and final production
- In-house engineering and CNC machining to extremely tight tolerances
- Decades of experience in working with reticulated and other specialty foams
- Flexible production runs from small batches to large-scale fabrication
- Problem-solving approach for integrating foam into wider systems
Our team understands the tolerances, behaviours and properties of specialty foams—including branded and high-performance options—better than anyone in the industry. We work with our customers to maximise performance, reduce costs, and streamline production by delivering fully optimised foam solutions.
Get a bespoke reticulated foam solution
If you’re looking for a foam converter who understands the needs of critical industries and offers genuine value in design, engineering and supply chain simplification—Kewell Converters is ready to help.
We’ll help you select the right foam materials, optimise your designs, and deliver custom foam parts that perform reliably in the real world.
FAQs
Reticulated foam has an open-cell structure with removed membranes, creating a breathable, porous network ideal for controlled airflow, filtration, and drainage—unlike standard foams which may restrict flow.
It’s commonly used in defence, aerospace, medical, marine, and industrial applications—especially where air or fluid control, lightweight performance, and durability are critical.
Yes, it offers excellent drainage and dries quickly. It’s also resistant to mild chemicals and cleaning agents, making it suitable for hygiene-critical and outdoor environments.
Absolutely. We offer multiple pore sizes (PPI grades) and custom formats—including sheets, blocks, and precision-cut components—tailored to your specific performance requirements.
