Medical Foam Supplies for the Healthcare Industry
Custom medical foam products add comfort, flexibility, and functionality across many healthcare settings. From orthopedic supplies and positioning wedges to prosthetic foam pads and medical-grade cushioning for surgical equipment, Merryweather’s medical foam improves the patient experience and supports better outcomes. Our ISO 13485:2016 and ISO 9001:2015 certified quality management systems meet the standards expected in hospitals, surgical suites, and other clinical environments. Whether you’re prototyping a medical device or specifying an adhesive foam pad, we can support you with our medical foam fabrication capabilities and sampling options.
Applications for Medical Foam Products
Merryweather Foam is a US-based custom foam manufacturer that designs and produces medical foam supplies under ISO 9001:2015 and ISO 13485:2016 quality systems. Using PORON® Microcellular Urethane, reticulated polyurethane, cross-linked polyethylene, and more than 1,300 other materials, we fabricate prosthetic pads, positioning wedges, custom orthotics, filters, and protective packaging that improve patient experience and clinical outcomes.
| Application | Specific Use | Material | Benefit |
|---|---|---|---|
| Medical Positioning Devices | Foam wedges that hold a limb or torso in place during procedures and recovery | Reticulated polyurethane, open-cell polyurethane | Eases discomfort and supports proper healing during therapy |
| Sound Dampening | Acoustic foam lining walls and partitions in offices, clinics, and surgical suites | Open-cell polyurethane, urethane (esters and ethers) | Keeps patient conversations and sensitive information private |
| Prosthetic Devices | Foam pads set between hard prosthetic parts and the patient’s skin | PORON Microcellular Urethane, open-cell polyurethane | Reduces skin abrasion and improves daily comfort |
| EKG Pads | Gel-impregnated foam pads placed on the skin during readings | Reticulated polyurethane | Delivers accurate readings without the messy step of applying gel |
| Orthotic Inserts | Shaped foam inserts worn inside footwear | PORON Microcellular Urethane, memory foam (viscoelastic) | Relieves painful foot conditions with durable, lasting support |
| Blood Filtration & Oxygenation | Reticulated foam filters inside heart-lung machine circuits | Reticulated polyurethane | Breaks up air bubbles to keep blood safe for circulation |
| Air Filtering | Foam filters in facility air systems and respiratory devices such as nebulizers | Reticulated polyurethane | Cleaner air for facilities and reliable delivery in respiratory care |
| Medical Device Packaging | Custom foam inserts and sheets that cradle devices and components in transit | Cross-linked polyethylene (XLPE), extruded polyethylene | Protects biologics and delicate machinery from transport damage |
Your Outsource Medical Foam Manufacturing Partner.
Bring us your medical supplies challenge and we’ll help you solve it. A family-owned U.S. foam manufacturer, Merryweather builds relationships with medical industry customers across every stage of the process, from prototyping to production to custom foam sheets for medical equipment packaging.
Find Our Custom Foam Manufacturing Facilities
Regional Foam Sourcing and Just-in-Time (JIT) Delivery From Three U.S. Locations
Merryweather Foam operates three foam fabrication facilities in distinct U.S. regions: its corporate headquarters in Barberton, Ohio, near Akron; a Southeast plant in Sylacauga, Alabama; and a Southwest plant in Anthony, New Mexico, near El Paso. This footprint lets Merryweather Foam ship custom foam from the site closest to your operation, cutting transit distance and supporting just-in-time (JIT) delivery. Manufacturers across the Midwest, Southeast, and Southwest can source from a nearby regional foam supplier while still getting nationwide shipping and ISO 9001:2015-certified quality. Because all three sites follow the same certified processes, part quality and lot-to-lot consistency hold steady regardless of which location fills the order.
Ohio
New Mexico
“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
Merryweather Offers More Services to a Wide Range of Industries
From design and engineering, assembly, foam printing, laminating and a wide range of CNC capabilities… Merryweather foam offers speed, precision and high quality.
Merryweather In-House Services
Make Merryweather Foam is your one-stop shop for a full range of industrial foam manufacturing services. Learn more below about all of our in-house capabilities – all available in one, LEAN-operated, efficient location.
Frequently Asked Questions
Does Merryweather Foam supply medical-grade cushioning for surgical equipment?
Yes. Merryweather Foam supplies medical-grade cushioning for surgical equipment, producing custom foam components from PORON® Microcellular Urethane, reticulated polyurethane, and more than 1,300 other materials under ISO 9001:2015 and ISO 13485:2016 certified quality systems.
Based in the United States and family-owned since 1948, Merryweather Foam fabricates cushioning built for the durability, hygiene, and batch-to-batch consistency that surgical environments demand. For equipment used in and around the operating room, our medical cushioning supports applications such as:
- Positioning wedges that immobilize a limb or torso during procedures and recovery, cut from reticulated and open-cell polyurethane
- Cushioning and gasketing inside surgical devices and instruments, where PORON's elasticity and superior recovery absorb impact and seal components
- Foam that withstands common cleaning solvents and offers low-outgassing, non-fogging performance for enclosed and sterile-adjacent spaces
- Sound-dampening foam for surgical suites and clinics that helps keep patient conversations private
Because firmness and density determine how cushioning performs, Merryweather Foam matches each component to your load and feel requirements, using lower-density foam for soft cushioning and higher-density foam for maximum support. Our foam fabrication capabilities include CNC water jet cutting, precision skiving, and die cutting, and we support every project from prototype and sampling through full production. To scope a surgical cushioning component, request a quote and our team will help identify the right material and process.
Is Merryweather Foam a PORON® foam supplier for medical device cushioning in the United States?
Yes, Merryweather Foam is a United States-based supplier of PORON foam for medical device cushioning, fabricating custom components from a microcellular urethane that rebounds to 99.8% of its original thickness for predictable, long-lasting support.
Developed by Rogers Corporation, PORON foam earns its place in medical devices because it resists compression set, withstands common cleaning solvents, and delivers consistent batch-to-batch performance, the qualities that separate durable cushioning from foam that flattens and fails. Merryweather Foam converts Rogers PORON Medical grades to match the load, firmness, and feel your device requires:
- PORON Medical Urethane Firm, an open-cell grade in 15 to 20 pound densities suited to applications that need energy absorbency
- PORON Medical Urethane Slow Recovery, a low-resilience grade that compresses slowly to create a custom, conforming fit
- PORON Medical Urethane Soft, a versatile grade in 15 and 20 pound densities for most cushioning applications
- DermaBak, a related skin-care material used in the backings of wound dressings
Because PORON die-cuts cleanly and accepts a wide range of pressure-sensitive adhesives, Merryweather Foam can deliver finished, adhesive-laminated cushioning ready to drop into your assembly. With manufacturing in Ohio, Alabama, and New Mexico, we keep PORON cushioning sourced and produced domestically. To request PORON samples or pricing for a device program, request a quote.
Does Merryweather Foam fabricate custom foam sheets for medical equipment packaging?
Yes, Merryweather Foam fabricates and custom fits foam sheets and inserts for medical equipment packaging, using cross-linked polyethylene (XLPE), extruded polyethylene, and other protective foams to cradle devices and components safely in transit. A device that arrives damaged means costly returns and program delays, so Merryweather Foam engineers packaging foam around your product's geometry and fragility to absorb shock, insulate sensitive contents, and protect everything from biologics to delicate machinery. Our custom foam capabilities for medical packaging include:
- Custom foam sheets, planks, and cavity inserts cut to the exact dimensions of your device or kit
- Protective materials such as XLPE and extruded polyethylene, closed-cell foams that resist permanent deformation over repeated handling cycles
- Precision fabrication by CNC water jet cutting, precision skiving, hot wire form cutting, and flatbed or rotary die cutting for clean, repeatable parts
- In-house custom kitting, packaging, bagging, and tagging so components ship ready for your line
As a United States foam manufacturer working under ISO 9001:2015 and ISO 13485:2016 certified quality systems, Merryweather Foam supports medical packaging from prototyping and sampling through full production, with custom design and engineering help at every step. With more than 1,300 materials on hand and the ability to respond in hours rather than days, we can match the right protective foam to your packaging spec. To start a medical packaging project, request a quote.
What makes Merryweather Foam a trusted foam fabrication partner for medical manufacturers?
Merryweather Foam is a trusted foam fabrication partner for medical manufacturers because it combines ISO 9001:2015 and ISO 13485:2016 certified quality systems with more than 75 years of United States foam manufacturing, in-house engineering, and a library of over 1,300 materials. When medical and surgical OEMs evaluate a foam partner, the factors that matter most map directly to what Merryweather Foam delivers:
- Medical quality systems: Merryweather Foam operates under ISO 13485:2016 and ISO 9001:2015 certifications, the quality framework medical device teams expect from a component supplier.
- Material expertise: With PORON® Microcellular Urethane, reticulated polyurethane, cross-linked polyethylene, and more than 1,300 materials, our team helps you select the right foam for cushioning, filtration, or packaging instead of forcing a one-size-fits-all spec.
- In-house engineering and fabrication: Custom design and engineering, CNC cutting, precision skiving, die cutting, slitting, and adhesive lamination all happen in one lean-operated facility, which protects consistency from prototype to production.
- Domestic, scalable sourcing: With plants in Ohio, Alabama, and New Mexico, Merryweather Foam keeps medical foam produced in the United States for more stable lead times and supply.
- Responsiveness: We respond quickly and provide samples so your team can validate fit and feel early.
Family-owned since 1948, Merryweather Foam works as an extension of your design team across every fabrication capability. To start a project, request a quote.
Custom Foam Medical Examples
Face Shield
Intubation Piece
Wrist Straps
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 applications.
- Available in many densities, thicknesses, and surface finishes.
Medical Application Case Studies
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Seven Surprising uses for Reticulated Foam
Ever unloaded the dishwasher and found the spoons or knives didn’t come clean because they were stuck together? Well imagine that happening with surgical instruments.
Read More -
Measuring Brain Waves Using Open Cell Foam
A leading provider in the healthcare sector was in need of a solution to prevent saline testing fluids from leaking from skull caps worn by EEG testing patients.
Read More
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.
