What Foam Factory does

Foam Factory is a family-owned foam fabricator and direct-to-consumer retailer operating from a roughly 310,000-square-foot facility in Macomb, Michigan. Founded in 1997 and family-financed throughout its history, the company combines in-house foam manufacturing with a self-serve e-commerce storefront at thefoamfactory.com, offering both standard-size SKUs and computer-controlled custom-cut foam to specification. The current CEO is Asma M Jahangir. The business maintains continuous BBB Accredited Business membership since 1997 and TrustedSite certification as its principal consumer-trust signals.

The product catalog is broad for a single-site operator and spans conventional polyurethane foams (Poly, Super Soft, HD36, Lux, Super Max, Qualux), viscoelastic memory foam in three density tiers (3LB ViscoSAVER, 4LB ViscoPLUSH, 5LB ViscoMAX) with warranties of 10–15 years, Dunlop latex bedding foam, packaging foams, acoustic foam, medical foam, Dryfast outdoor foam, closed-cell foams, rebond foam, and gym rubber. Accessories include Dacron polyester fiberfill, poly-cotton knit and striped polyester mattress covers, and Avery Dennison FBR 8950 adhesive backing. Custom cutting is executed via computer-controlled machinery enabling same-day custom orders, which the company markets as its primary manufacturing differentiator.

Commercially, Foam Factory runs a pure-play DTC distribution model: orders are placed online with free FedEx Ground shipping on purchases over $100 within the contiguous US, and a 10% price-match guarantee underwrites competitive positioning. Revenue is generated entirely through one-time product sales and custom fabrication services with no subscription, licensing, or recurring components. Customer segments are heterogeneous, with DIY/home consumers as the primary cohort and industrial/commercial, marine/outdoor, pet owners, and fitness/athletic users as named secondary segments. The company claims a global presence but operates from a single Southeast Michigan site, indicating that international reach is fulfilled via US shipping rather than local distribution.

Name

Foam Factory

Legal name

Foam Factory, Inc.

Website

https://thefoamfactory.com

Company type

Private

Founded year

1997

Operating status

Operating

Headcount range

11–50 employees

Short description

Foam Factory is a family-owned foam fabricator and direct-to-consumer retailer based in Macomb, Michigan, serving DIY consumers, industrial buyers, marine/outdoor users, pet owners, and fitness customers with a broad foam catalog and computer-controlled custom cutting through thefoamfactory.com.

Ownership category

akta.pro rank

Product category

Foam Products Manufacturing

NAICS

Urethane and Other Foam Product (except Polystyrene) Manufacturing (326150), Polystyrene Foam Product Manufacturing (32614)

SIC

Plastics Foam Products (3086)

akta.pro primary industry

Foam Conversion & Fabrication (Cutting, Laminating, CNC, Packaging Inserts) (IMANAIAJ)

akta.pro secondary industries

Foam Protective Packaging (EPS/EPE/EPP, PU, Molded Foam) (IMALAFAA), Polymer Foams & Cellular Materials (PU Foams, EPS/XPS, Structural Foams) (IMAEANAL), Polyurethane (PU) Flexible Foam Manufacturing (IMANAIAC), Polyethylene (PE) Foam Manufacturing (IMANAIAE)

Keywords

• Foam fabrication products
• Custom foam cutting
• Memory foam mattresses
• Upholstery foam supplies
• Industrial foam materials

Headquarters

HQ city

Macomb

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2C

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Operations, Personnel, Marketing or Sales, Infrastructure

Revenue model

1. Foam Product Sales: One-time purchase of foam materials including mattresses, cushions, packaging foam, acoustic foam, and specialty foams. Products sold in standard sizes and custom-cut configurations. Revenue from individual product transactions with varying price points based on foam type, density, and size.
2. Custom Fabrication Services: Custom cutting services for bespoke foam products. Customers provide specifications for custom dimensions; Foam Factory cuts foam to exact requirements. Additional margin earned on value-added fabrication.
3. Accessories and Supplies: Sale of complementary products including polyester fiberfill (Dacron), mattress covers, and adhesives. These accessories accompany primary foam product purchases.

Pricing tiers

Go-to-market motion2 records

Distribution channels2 records

Marketing channels5 records

Core offering

Foam Factory fabricates and distributes foam, rubber, sponge, and upholstery products for both consumer and industrial applications through a direct-to-consumer e-commerce model. The company produces memory foam mattresses, conventional foams, specialty bedding foams, packaging foams, acoustic foam, medical foam, dryfast foam, closed-cell foams, rebond foam, and related accessories from a ~310,000 sq ft facility in Macomb, Michigan.

Product overview

Foam Factory is a family-owned foam manufacturing and retail company operating from a 310,000 square foot facility in Southeast Michigan for over 30 years. The company offers a comprehensive portfolio of foam products including conventional foams (Poly, Super Soft, HD36, Lux, Super Max), specialty bedding foams (3LB/4LB/5LB Memory Foam, Dunlop Latex), packaging foams, acoustic foam, medical foam, closed-cell foams, and related accessories. Their product ecosystem combines manufacturing and retail operations with custom cutting services, offering both individual consumer products like mattresses and cushions, as well as industrial-grade materials. Key accessories include Polyester Fiberfill (Dacron) wraps, adhesive backings (Avery Dennison FBR 8950), and mattress covers in poly-cotton and striped polyester. The company serves both individual consumers and businesses with customization capabilities and same-day custom-cut cushion services.

Differentiator

Problem solved

Functional benefit

Products and services

• Memory Foam Mattresses Bedding mattresses made from viscoelastic memory foam, sold to individual consumers seeking residential sleep products.
• Conventional Foams Standard polyurethane foams for general upholstery, cushioning, and craft applications, sold to consumers and small businesses.
• Specialty Bedding Foams Foams engineered for bedding use such as toppers and mattress components, targeting residential consumers.
• Packaging Foams Foam inserts and packaging materials used to protect goods during shipping and storage, sold to small businesses and consumers.
• Acoustic Foam Foam panels and tiles designed for sound absorption in studios, home theaters, and commercial spaces.
• Medical Foam Foam materials used in medical cushions, supports, and healthcare applications where specific foam grades are required.
• Dryfast Foam Quick-drying foam designed for outdoor and marine applications where moisture resistance is needed.
• Closed-Cell Foams Closed-cell foam sheets and shapes that resist water absorption, used for insulation, flotation, and gasket applications.
• Rebond Foam Recycled rebond foam made from bonded foam scraps, used for padding, carpet underlay, and upholstery applications.
• Foam Accessories Accessory items related to foam products including covers, adhesives, and complementary components.

Quantifiable outcome

• Memory foam mattresses with 3LB, 4LB, 5LB densities provide varying contouring precision and support levels
• +3 more outcomes

Segments5 records

Ideal customer profiles2 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature4 records

Scale indicators4 records

Recent moves4 records

Expansion highlights5 records

Broad incumbents

• Tempur Sealy International: Global bedding manufacturer offering memory foam mattresses under Tempur-Pedic, Sealy, and Stearns & Foster brands. Direct competitor in the memory foam mattress category where Foam Factory's ViscoSAVER/ViscoPLUSH/ViscoMAX line is positioned.
• FXI (formerly Foamex International): One of North America's largest manufacturers of polyurethane and engineered foam products serving bedding, furniture, and industrial markets. Overlaps with Foam Factory across conventional and specialty foam categories but operates at significantly greater scale and broader market reach.
• Carpenter Co. Large vertically integrated producer of polyurethane foam, polyester fiber, and cushioning products used in bedding, furniture, and packaging. Comparable to Foam Factory in product mix but serves primarily B2B with much larger manufacturing scale.
• Leggett & Platt: Diversified manufacturer of engineered components including bedding foam, mattress innersprings, and cushioning materials. Comparable in the bedding foam category where Foam Factory's memory foam mattresses compete, though Leggett & Platt is primarily a B2B component supplier.

Emerging players

• Casper Sleep: Direct-to-consumer mattress brand known for its memory foam and hybrid mattresses. Competes with Foam Factory's memory foam mattress line via a more digitally mature D2C storefront and stronger brand recognition, though with significantly higher customer acquisition costs.
• Soundproof Cow: Specialty online retailer focused on acoustic foam panels and soundproofing products. Comparable to Foam Factory in the acoustic foam product category, but specialized entirely in sound treatment applications rather than a broader foam catalog.

Direct peers

• Foam Supplies Inc: Specialty foam manufacturer and fabricator offering custom-cut polyurethane and specialty foams to industrial and consumer customers. Comparable to Foam Factory in product breadth and custom fabrication capabilities, though with stronger industrial focus.
• The Foam Store: Online foam retailer offering custom-cut foam for cushions, mattresses, and upholstery applications. Highly comparable D2C model targeting DIY consumers, with similar custom cutting value proposition and price transparency.
• Rempac Foam Corp. Foam fabricator and distributor producing polyurethane, polyethylene, and packaging foams for industrial, packaging, and consumer applications. Closely comparable to Foam Factory in product mix, with similar custom fabrication capabilities.

Regional players

• Foam N' More & Upholstery: Mid-Atlantic foam fabricator and upholstery supplier serving furniture, marine, and automotive markets. Comparable to Foam Factory in foam fabrication and custom cutting services, but with a more regional US footprint and B2B focus.

Market position

Strengths4 records

Weaknesses4 records

Competitive moat4 records

Key risks5 records

Key highlights6 records

Customer concentration

• LinkedInlinkedin.com/company/foam-factory

Compliance2 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Foam Factory