We Make Custom Foam Products
Custom Foam Fabrication & Manufacturing Solutions
Merryweather Foam is a U.S.-based foam manufacturer specializing in custom foam fabrication and foam converting. With over 1,000 foam materials—including polyurethane foam, polyethylene foam, silicone foam, and rubber foam—we support applications across healthcare, automotive, electronics, and industrial markets. From design and prototyping to CNC cutting, lamination, and full contract manufacturing, we deliver precision foam components that meet performance requirements and scale with your production.
Why Manufacturers Choose Merryweather Foam
Manufacturers choose Merryweather Foam for material expertise, precision foam fabrication, and reliable production. We support OEM manufacturers and industrial product teams by helping reduce lead times, improve product performance, and streamline sourcing through a single, experienced foam manufacturing partner.
ISO Certifications
We meet ISO 9001:2015 and ISO 13485:2016 standards for foam fabrication, lamination, and distribution—ensuring consistent quality for medical, industrial, and OEM applications.
Part Number Serialization
Every custom foam component is assigned a unique part number for full traceability and repeatable manufacturing performance.
Responsive Support
We respond in hours, not days—with fast quotes, rapid prototyping, and direct access to a knowledgeable team that keeps your project moving.
Custom Foam Materials
Merryweather Foam offers over 1,300 foam materials, including polyurethane foam, polyethylene foam, silicone foam, PORON® urethane, and specialty rubber foams engineered for sealing, cushioning, insulation, and acoustic control.
PORON® Microcellular Urethane
Extruded Polyethylene
Reticulated Polyurethane Foam
Urethane (Esters and Ethers)
Common Applications:
Cushioning, Packaging, Sound dampening
BISCO® Silicone Foam
Low Permeability Foam
Sponge Rubber
Cross-Linked Polyethylene
Our Manufacturing Capabilities
“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
“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
“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.
Industry Trusted
Get a Quote for Your
Custom Foam Project
Connect with Merryweather Foam to discuss your custom foam fabrication or contract manufacturing needs. We’ll help identify the right materials and processes.
