Foam engineered for life

partially recycled foam blocks, introducing more sustainable products

Bespoke case insert using lamination process of 2 colours and routed on our CNC machine

Our skilled engineers deep in discussion in the factory

What we do

Welcome to Kewell Converters, the UK’s leading specialist in foam fabrication and conversion. Established in 1971, we have over 50 years of experience in delivering bespoke, high-quality foam products tailored to meet the unique needs of our diverse clientele.

Industries we serve:

Aerospace: Foam for cabin interiors, insulation panels, and lightweight components
Defence & military: MOD-grade inserts, body armour, and equipment insulation
Industrial engineering: Seals, gaskets, HVAC insulation, buoyancy foam and marine fenders
Medical & healthcare: Prosthetics, orthopaedics, and comfort-focused device applications
Transit & product packaging: Durable foam inserts and energy-absorbing, multi-use solutions
Construction: Thermal insulation, soundproofing, and scaffold bumpers

Why choose Kewell Converters?

Advanced CAD/CAM design and CNC precision manufacturing
ISO 9001:2015 certified for impeccable quality
Comprehensive selection of foam materials
Certified partner of Zotefoams Plc
Over 50 years of expertise in solving complex foam needs
Independent ethical business offering a flexible service that delivers customised solutions

Contact Kewell Converters today to explore how we can support your custom foam requirements

Find out more

We have been providing bespoke, quality, UK manufactured foam and a wide variety of applications since 1971.

We have relied on Kewell Converters to accurately translate quite complex drawings for more than a decade. We would recommend them for difficult work.

Director, UK Defense Industry

Quick turnaround of samples and advice on feasibility issues, quality of products supplied usually to the standard expected or above, and expectations met in terms of lead times.

Product Manager, UK Innovation

Flexible with improving designs and working with sometimes inadequate files, quote turnaround time usually same day and good communication.

Managing Director, UK Promotional

two different colours of foam laminated together

Manufacturing

Recognised as the foremost specialist in foam fabrication and conversion for batch production components within the UK, our profound expertise in manufacturing and design sets us apart.

Leveraging the prowess of advanced CAD/CAM design and programming, combined with precision-driven CNC multi-head/axis foam routing, we’re primed to deliver bespoke foam solutions.

At Kewell Converters, we use the latest in water jet cutting technology in our foam manufacturing process. This ensures sharp clean edges and a high-calibre result that isn’t possible with conventional press tools.

With foam moulding, the applications are almost endless. We’re able to deliver versatile solutions for numerous industry sectors from automotive and furniture manufacturing to window and door frames.

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example of textures that can be added to foam

Materials

Kewell Converters stands as an esteemed independent distributor and accredited fabricator for Zotefoams. We proudly represent their range: Azote® (including Plastazote®, Evazote®, Supazote®, Ecozote ® and Propozote®) and Zotek® block foams. Our longstanding association ensures we can offer an extensive variety of foam grades, types, sizes, and thicknesses.

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Aviation industry is one of many where converted foam is used

Industries

Since our inception, we’ve been at the forefront of delivering impeccable engineering, design, and manufacturing solutions in foam to a diverse spectrum of industries.

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Keep in touch

Splitting process of foam, removing the top layer called skin

Family-run business

Established in 1971, Kewell Converters remains a family-owned and operated business. Our heritage is deeply embedded in our corporate ethos, and it shines through in every endeavour. Clients consistently appreciate our transparent approach, underscoring our commitment to openness and integrity. Our meticulous attention to detail, coupled with our design prowess, equips us to address even the most intricate design and fabrication challenges.

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We are bespoke

At Kewell Converters, we excel in the design and manufacture of tailored foam products, aligning seamlessly with your specifications. Our core expertise lies in creating both bespoke and custom foam components, reflecting our unwavering commitment to precision and quality. Whether you provide us with hand-drawn sketches or CAD/CAM software outputs, we adeptly translate your visions into tangible solutions. Addressing design challenges ranging from straightforward to intricate, we ensure meticulous machining and fabrication, preparing foam products that are market-ready and up to industry standards.

We value quality

Quality isn’t just an aspiration—it’s a defining ethos for us. Our exemplary track record in design and manufacturing is manifested by our esteemed blue-chip clientele, contributing significantly to our turnover. We cherish our heritage and are recognized within the foam converting industry for our unparalleled quality and technical prowess. Upholding the highest industry standards, we operate in strict adherence to the ISO 9001:2015 quality management system.

We are excellent at precision

Specialising in high-tolerance foam fabrication and products, Kewell Converters stands at the pinnacle of foam expertise. Backed by a dedicated design team and years of manufacturing acumen, we are adeptly positioned to partner with you. Whether addressing challenges in performance, durability, or economic efficiency, we craft high-performance foam solutions tailored to consistently deliver on the specific requirements of your processes and applications.

Sustainability at the forefront

Our unwavering dedication to environmental stewardship and the principle of long-term sustainability is evident in every facet of our operation. We conscientiously strive to reduce our environmental footprint, ensuring a balance between our business endeavours and the greater good. We innovate in product design and manufacturing techniques to boost yields, ensuring the meticulous reduction of scrap and offcut processing. Through these endeavours, we are not only advancing our industry but also safeguarding our planet’s future.

Innovation is in our DNA

We’re curious and good at problem solving, continuing to push boundaries using new techniques and materials. We never stand still and invest in new technologies.