Celebrating World Engineering Day with Kewell Converters: engineering excellence in foam conversion

Shaping the future of foam engineering

For over 50 years, Kewell Converters has been at the forefront of foam conversion, continuously pushing the boundaries of engineering to deliver the very best solutions across aerospace, defence, industrial engineering, medical, transit, and construction sectors.

It all began in a humble garage, where Colin Kewell took his first entrepreneurial steps. Today, under the leadership of his sons, Nick and Marcos—both engineers by trade—Kewell Converters has grown into a respected name synonymous with innovation, precision, and engineering expertise.

This World Engineering Day, we celebrate not only the global community of engineers but also our incredible in-house team whose passion and ingenuity continue to drive exceptional results.

Engineering innovation: always asking, “how can we do this better?”

Engineering at Kewell Converters is not just about cutting foam—it’s about pioneering new approaches to problem-solving. Managing Director Nick Kewell encapsulates this ethos: “We continually look at what we do and ask how we can do it better. We invest time in seeing what’s out there, applying ideas from outside our industry to drive innovation.”

Whether it’s adapting a machining process designed for metal to create ultra-thin foam tubing for the racing industry or leveraging cutting-edge moulding technologies, we don’t shy away from challenges. Our ethos is simple yet powerful: stay curious, ask questions, and always look for ways to improve.

General Manager Neil Johnston reflects on one milestone that epitomises this perseverance. Two years ago was a defining moment at Kewell Converters as we acquired a state-of-the-art Fastweld machine, a project that was years in the making.

“It was something I had pushed for, as I could see the huge advantage it would give us. It’s fast, user-friendly, and consistently delivers excellent results. There are only two of its kind in the country.”

Precision engineering: no shortcuts, only excellence

When working with high-performance materials such as those used in aerospace and the military, precision is non-negotiable. Sales Manager Scot Mackay highlights the company’s rigorous approach: “We continuously analyse our capabilities, ensuring we meet ISO 9001 standards and focus on developing the best working practices and materials.”

At Kewell Converters, every project undergoes meticulous CAD design treatment. “Attention to detail is crucial—it all starts with our Pre-Production team,” Scot explains. “The drawing is the foundation of an engineered design solution, laying out dimensions, tolerances, and critical areas that need approval by the customer.” This process not only ensures accuracy but also provides customers with confidence in the final product.

The power of advanced technology in foam fabrication

Kewell Converters utilises state-of-the-art equipment, from CNC contour cutting to laser engraving, ensuring precise and efficient manufacturing. Scot talks about one of their technological breakthroughs: “Our CNC Contour machine can achieve an accurate cut up to 1.2m in length without the need for laminating smaller sections with adhesive. This means we can create components in one solid piece, depending on design, eliminating weak points and enhancing durability.”

This expertise allows us to produce superior foam parts for critical applications, whether for aircraft cabin interiors, body armour inserts, or medical prosthetics.

Sustainability, too, is woven into our technological choices. With 200 solar panels powering 20% of our production facility and innovations like voltage optimisation and intelligent air-conditioning systems, we’re embedding green principles into our daily operations.

Team spirit and agility

Beyond machinery and processes, our real strength lies in our people. At Kewell Converters, our collaborative team culture sets us apart. Scot Mackay explains it well:

“Communication between departments is close. We are nimble, able to react quickly, and ensure everyone is aware of customer expectations,” says Scot. “Our customers are part of the fabric that has built Kewell Converters.”

Nick Kewell adds “Feeling you are part of something positively affects your mindset and approach. When we work together to tackle challenges, the outcome is always stronger.”

Engineering for the future

The future of engineering is about balancing performance, cost, and sustainability—and we’re committed to being part of the solution. From exploring recycled materials to developing more eco-friendly processes, we’re tackling the challenges of responsible engineering head-on.

Nick reflects on this responsibility, offering his perspective on sustaining innovation in our sector:

“The engineer in me wants to solve problems, to design and manufacture products in a better way. With continued investment in R&D and collaboration across industries, we can meet environmental demands without compromising performance.”

AI and machine learning offer another exciting avenue for growth. Though still emerging tools in foam fabrication, these technologies promise to revolutionise CAD designs, optimise production, and reduce waste. We’re certainly intrigued and excited on how AI can influence critical processes, ensuring we remain a step ahead in a rapidly evolving field.

The Kewell Converters commitment

At Kewell Converters, engineering runs deep through our DNA. Whether we’re innovating foam insulation for racing cars, crafting medical-grade prosthetics, or delivering state-of-the-art defence solutions, our engineers embody our values of quality, creativity, and ethical craftsmanship.

Neil Johnston encapsulates our vision for the future, noting the subtle yet significant shifts in materials and production processes in recent years. “From our roots in Zotefoams to exploring new materials and technologies, we’re continually evolving to meet and exceed customer demands.”

This World Engineering Day, we champion the problem solvers and innovators who make extraordinary solutions possible. Thank you to our engineers, our partners, and our clients for trusting us to tackle complex challenges and deliver results that matter.

Interested in collaborating with us for your next project? Get in touch with our team and discover how precision engineering in foam fabrication can elevate your product design. Visit our History page to learn more about our rich legacy and expertise in engineering excellence.