The Global Die Cut Foam Market was valued at USD 13.85 Billion in 2024 and is projected to reach USD 18.92 Billion by 2030, growing at a Compound Annual Growth Rate (CAGR) of 5.3% during the forecast period (2024–2030). This growth is being driven by increasing demand from the packaging and construction industries, alongside the rising need for custom protective solutions in electronics, automotive components, and medical devices, particularly within the United States market.

As industries demand more specialized, lightweight, and cost-effective sealing, cushioning, and insulating materials, the die cut foam market is experiencing significant transformation. The market leaders are innovating with advanced materials like specialty polyurethanes and cross-linked polyethylenes to meet stringent performance requirements. In this blog, we profile the Top 10 Companies in the Die Cut Foam Industry—a diverse group of manufacturers and fabricators shaping the future of precision foam components globally and in the U.S.

Download FREE Sample Report: Global and United States Die Cut Foam Market – View in Detailed Research Report

---

🔟 1. Thrust Industries

Headquarters: St. Charles, Illinois, USA
Key Offering: Polyurethane, Polyethylene, Neoprene, and Custom Foam Fabrication

Thrust Industries is a prominent custom foam fabricator in the United States, serving a wide array of industries including automotive, aerospace, and medical. They specialize in converting foam materials into precise gaskets, seals, and cushioning components using advanced die-cutting technologies.

Innovation and Capabilities:

• Advanced CNC routing and die-cutting services

• Specialization in flame-retardant and UL-rated foam materials

• Just-in-time manufacturing and kitting services for large-scale clients

---

9️⃣ 2. Marko Foam Products

Headquarters: St. Louis, Missouri, USA
Key Offering: Polyester, Polyether, and Specialty Foam Die-Cutting

Marko Foam Products is a leading supplier and converter of foam materials, with a strong focus on the packaging and industrial sectors. The company provides custom die-cut solutions for protective packaging, acoustic insulation, and filtration applications.

Innovation and Capabilities:

• Wide material selection including convoluted and anti-static foams

• In-house lamination and fabrication for complex multi-layer components

Download FREE Sample Report: Global and United States Die Cut Foam Market – View in Detailed Research Report

---

8️⃣ 3. Foam Products Corporation

Headquarters: Lodi, New Jersey, USA
Key Offering: Polyethylene, Polyurethane, and Cross-Linked Foam Die-Cuts

Foam Products Corporation is a major U.S.-based manufacturer and distributor of foam sheets and rolls, with extensive die-cutting capabilities. They cater to the construction industry for weather sealing and to the packaging industry for protective inserts.

Innovation and Capabilities:

• Custom fabrication of foam tapes and adhesive-backed components

• Supplies major home improvement retailers and construction wholesalers

---

7️⃣ 4. Williams Foam

Headquarters: Iuka, Mississippi, USA
Key Offering: Polyurethane Foam, Rebond Carpet Underlay, Die-Cut Parts

Williams Foam is a significant manufacturer of flexible polyurethane foam, with a strong presence in the Southern United States. The company produces both raw foam and fabricated die-cut parts for the furniture, bedding, and automotive aftermarkets.

Innovation and Capabilities:

• Vertical integration from foam pouring to precision die-cutting

• Specializes in high-resiliency and high-density foam formulations

---

6️⃣ 5. HEUBACH Corporation

Headquarters: Port Washington, Wisconsin, USA
Key Offering: Technical Foam Components, Gaskets, Seals

HEUBACH Corporation specializes in high-performance foam die-cutting for technical applications. They serve the medical, electronics, and automotive industries with components that require tight tolerances and specific material properties like chemical resistance.

Innovation and Capabilities:

• Focus on medical-grade silicones and closed-cell foams for sealing

• Cleanroom manufacturing capabilities for medical device components

---

5️⃣ 6. Brooklyn Products

Headquarters: Brooklyn, New York, USA
Key Offering: Custom Foam Inserts, Packaging Solutions, Polyester and Polyether Foams

Brooklyn Products is a key player in the custom packaging foam market, providing tailored die-cut inserts for shipping electronics, delicate instruments, and consumer goods. Their expertise lies in creating cost-effective protective solutions for e-commerce and logistics companies.

Innovation and Capabilities:

• Rapid prototyping and short-run production for packaging designs

• Focus on sustainable and recyclable foam packaging options

---

4️⃣ 7. Marian Inc.

Headquarters: Indianapolis, Indiana, USA
Key Offering: Adhesive-Backed Foam Tapes, Die-Cut Gaskets, Multi-Material Laminates

Marian Inc. is a global provider of engineered adhesive solutions, with a significant business in die-cut foam tapes and seals. They are a critical supplier to the automotive OEM market for applications like trim attachment and weather sealing.

Innovation and Capabilities:

• Proprietary adhesive formulations for harsh environments

• Global manufacturing footprint supporting just-in-sequence delivery

Download FREE Sample Report: Global and United States Die Cut Foam Market – View in Detailed Research Report

---

3️⃣ 8. Rogers Corporation

Headquarters: Chandler, Arizona, USA
Key Offering: High-Performance Foams (PORON®), Silicones, Die-Cut Components

Rogers Corporation is a world leader in engineered materials, producing high-performance foams used in demanding electronics, transportation, and industrial applications. Their die-cut components are found in smartphones, electric vehicle batteries, and aerospace systems.

Innovation and Capabilities:

• Industry-leading PORON® polyurethane foam for sealing and cushioning

• Materials designed for extreme temperature, pressure, and chemical exposure

---

2️⃣ 9. Boyd Corporation

Headquarters: Pleasanton, California, USA
Key Offering: Elastomeric Foam Seals, Thermal Insulation, Acoustic Management

Boyd Corporation is a global technology innovator specializing in engineered materials and thermal management. Their die-cut foam division provides critical sealing and insulating solutions for the electronics, mobile computing, and medical industries.

Innovation and Capabilities:

• Advanced fabrication of silicone, fluorosilicone, and other specialty foams

• Integration of foam with other materials for multi-functional components

---

1️⃣ 10. Saint-Gobain Performance Plastics

Headquarters: Paris, France (with major U.S. operations in Ohio)
Key Offering: Specialty Foam Tapes, Coated Fabrics, Gasketing Materials

Saint-Gobain is a global giant in engineered materials, with a significant presence in the die-cut foam market through its Performance Plastics division. They supply sophisticated foam-based solutions for aerospace, semiconductor processing, and life sciences.

Innovation and Capabilities:

• Development of ultra-clean, low-outgassing foams for sensitive environments

• Global R&D and manufacturing network supporting complex supply chains

Get Full Report Here: Global and United States Die Cut Foam Market – View in Detailed Research Report

---

📊 Outlook: The Future of Die Cut Foam Is Smarter and More Sustainable

The die cut foam market is undergoing a dynamic evolution. While traditional protective packaging remains a core driver, the industry is rapidly advancing towards high-value technical applications, automation in fabrication, and the development of sustainable material alternatives.

📈 Key Trends Shaping the Market:

• Rising demand for lightweight and durable foam solutions in electric vehicle manufacturing

• Growth in custom protective packaging driven by the global e-commerce boom

• Increased adoption of automated and digital die-cutting technologies for precision and efficiency

• Strong focus on developing bio-based and recyclable foam materials to meet environmental regulations

Get Full Report Here: Global and United States Die Cut Foam Market – View in Detailed Research Report

The companies listed above are not only supplying essential components to countless industries—they’re driving the innovation and sustainability that will define the next generation of foam fabrication.