We Make Custom Foam Products

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white illustrated roll of material1,000+ Foam Materials Available
three layers of a solid material35,000 unique products made
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Why Merryweather?

At Merryweather Foam, we pride ourselves on our ability to combine experience, innovation and excellent customer service. We have the knowledge, manpower and equipment to help you get the job done.

We Produce Your Parts

Let us be your turnkey partner. Consider us your one-stop shop for all things foam fabrication.

Leading Foam Manufacturer Since 1948

We have been manufacturing custom foam products for over 75 years. We source, and deliver the right materials for Fortune 500 companies and family-owned businesses alike.

3 Locations to Serve You

Each of our manufacturing facilities in Ohio, Alabama and New Mexico is ISO 9001:2015 registered and has a local and dedicated customer team to help with your next project.

Part Number Seralization

We assign each foam item we manufacture a specific identifying number. This way, we can directly examine the manufacturing process that led to your product’s performance, and necessary adjustments can be made.

Custom Foam Materials

Choose from a selection of over 1,321 different types and sizes of foam materials.

PORON® Microcellular Urethane

Common Applications:

Gasketing, Gap-filling, Buzz, Squeak, and Rattle

Expanded Polyethylene

Common Applications:

Packaging

Reticulated Polyurethane Foam

Common Applications:

Filtration, Foam Wedges

Urethane (Esters and Ethers)

Common Applications:

Cushioning, Packaging, Sound dampening

Silicone

Common Applications:

High-temperature applications, Medical

Low Permeability Foam

Common Applications:

Gasketing

Sponge Rubber

Common Applications:

Insulation, Mousepads

Cross-Linked Polyethylene

Common Applications:

Insulation, Dunnage

See All Foam Materials
More Capabilities
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“My biggest challenge was deciding on which type of foam & silicone would best fit my needs. Because there are so many types of materials available, it can be time consuming to learn about all the different materials available and their specifications. Merryweather Foam was able to help me get the right materials that I needed to complete my product. Their work was completed on time – each and every time.“

Rob S. | Electronic Device Manufacturer

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“We struggled with getting the best design for two of our products. I was concerned that the final cost would be very expensive, but Merryweather worked closely with us to hit our product requirements and price point. After a few different samples, the foam parts were a perfect fit.“

Evan G. | Audio Equipment Manufacturer

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“My company handles over 10,000 products. The team at Merryweather has worked with me on many occasions to help me choose the right foam for the right application. Merryweather Foam is easy to work with and has helped me find solutions that I can pass along to my customers.“

Bill R. | Industrial Product Distributor

Featured Material Poron Microcellular Polyurethane

PORON® is a type of urethane foam developed by Rogers Corporation.

  • Rebounds to 99.8% of its original thickness
  • Excellent choice for many gasketing, gap-filling, buzz, squeak, and rattle applications.
  • Available in many densities, thicknesses, and surface finishes.
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Industry Trusted

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for Your Project

Our experts want to help you find the right solution to your foam challenges.

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