Rogers Foam Corporation

What Rogers Foam Corporation does

Rogers Foam Corporation is a privately held, family-owned custom foam fabricator and materials converter founded in 1947 and headquartered in Somerville, Massachusetts. The company converts flexible engineered materials — including polyurethane, polyethylene, cross-linked polyethylene, polypropylene, EPDM, neoprene, melamine foam (BASF Basotect), and specialty urethane/silicone foams (Rogers Corporation Poron and Bisco) — into precision parts through water jet cutting, high-speed die cutting, vertical and horizontal contour cutting, CNC routing, foam lamination, and molded urethane processes. Its in-house engineering team designs and builds custom production machinery and provides rapid prototyping, tooling, and design services. Rogers Foam serves OEMs and contract-manufacturing customers across automotive, medical, consumer goods, industrial, packaging, furniture/bedding, and military end markets, producing parts such as battery thermal separators, reticulated foam applicators, filtration foams, gaskets and seals, acoustic foams, specialty case inserts, and medical positioners.

The business operates through a quote-based direct sales model targeting enterprise OEM and contract-manufacturing customers, with manufacturing spanning 9 U.S. facilities and 4 Mexico facilities under the corporate umbrella, plus five wholly-owned operating subsidiaries (Amcon Foam, Vahala Foam, Capitol Foam, Cutters Foam, and Foam Fabricators of Minnesota) that extend geographic and application reach. Revenue is generated through one-time fabrication orders, recurring contract-manufacturing engagements, and value-added services including design engineering, rapid prototyping, custom machinery design/build, and global logistics with consignment inventory management. The company maintains an unusually broad certification portfolio — ISO 9001, ISO 13485, ISO 14001, IATF 16949, FDA 21 CFR Part 820 registration, ITAR/EAR registration, and SAM/CAGE registration — across its sites, qualifying it for regulated automotive, medical device, and federal/defense supply chains. Notable production achievements include delivering 1.5 million reticulated foam cosmetic applicators in under four months using two custom-built machines at 100,000 parts per week and developing hybrid vehicle battery foam separators that maintain operating temperatures within a -10C to 50C range for a Big-Three American automaker.

Name

Rogers Foam Corporation

Legal name

Rogers Foam Corporation

Website

https://rogersfoam.com

Company type

Private

Founded year

1947

Operating status

Operating

Headcount range

251–500 employees

Short description

Rogers Foam Corporation is a family-owned custom foam fabricator and materials converter founded in 1947, serving automotive, medical, consumer goods, industrial, packaging, and military OEMs across 13 manufacturing facilities in the U.S. and Mexico through wholly-owned subsidiaries.

Ownership category

akta.pro rank

Product category

Custom Foam Fabrication & Materials Conversion

NAICS

Urethane and Other Foam Product (except Polystyrene) Manufacturing (32615), Urethane and Other Foam Product (except Polystyrene) Manufacturing (326150), Plastics Product Manufacturing (3261)

SIC

Plastics Foam Products (3086), Fabricated Rubber Products, Nec (3060)

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), Polyurethane (PU) Flexible Foam Manufacturing (IMANAIAC), Polyurethane (PU) Rigid Foam Manufacturing (IMANAIAD), Polypropylene (PP) Foam Manufacturing (IMANAIAF)

Keywords

• Custom foam fabrication
• Foam materials conversion
• Contract manufacturing services
• Engineered foam parts
• OEM foam components

Headquarters

HQ city

Somerville

HQ country

United States

HQ region

North America

Offices12 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Personnel, Operations, Infrastructure, Technology or R&D, Marketing or Sales

Revenue model

1. Custom Foam Fabrication: Core business manufacturing custom foam parts for OEMs and end customers across medical, automotive, consumer goods, industrial, packaging, furniture, and bedding industries.
2. Contract Manufacturing Services: Full outsourcing of manufacturing process including assembly and final pack out services. Fabrication using customer-supplied material or complete manufacturing from start to finish.
3. Design and Engineering Services: In-house engineering team provides material solutions development, rapid prototyping, custom tooling and machinery design/build, and PLC-controlled semi-automated production lines.
4. Global Logistics Services: Logistics services including small ground shipments to Mexico/Canada, air/ocean shipments globally, consignment inventory management, and barcoding capabilities with manufactured lot traceability and individual unit serialized numbering.

Go-to-market motion2 records

Distribution channels3 records

Marketing channels4 records

Core offering

Rogers Foam Corporation converts flexible engineered materials into custom foam parts for OEM customers across automotive, medical, consumer goods, industrial, packaging, furniture, bedding, and military markets. The company fabricates polyurethane, polyethylene, polypropylene, EPDM, neoprene, and specialty foams using water jet cutting, die cutting, contour cutting, CNC routing, foam lamination, and molded urethane processes. It also offers contract manufacturing, design and engineering services, custom machinery design/build, and global logistics including consignment inventory management.

Product overview

Rogers Foam Corporation is a foam fabrication company offering custom engineered foam products and materials conversion services. The core offering is custom foam fabrication including molded urethane, water jet cutting, die cutting, contour cutting, CNC routing, and compression molding. The company operates multiple subsidiaries (Amcon Foam, Vahala Foam, Capitol Foam, Cutters Foam, Foam Fabricators of Minnesota) that extend its geographic footprint and application expertise. Their product portfolio includes application-specific solutions such as reticulated foam applicators for cosmetics, hybrid vehicle battery thermal management products, acoustic/sound control foams, comfort and support products, filtration foams, gaskets and seals, specialty packaging, medical positioners, surface protection, and thermal management products. They work with a comprehensive range of foam materials including polyurethane, polyethylene, polypropylene, cross-linked polyethylene, EPDM, neoprene, melamine foam, and specialty materials from partners like BASF (Basotect) and Rogers Corporation (Poron, Bisco). The company serves diverse markets including automotive, medical, consumer products, industrial, packaging, furniture, bedding, and military.

Differentiator

Problem solved

Functional benefit

Products and services

• Custom Foam Fabrication Services Custom conversion of flexible engineered materials (polyurethane, polyethylene, polypropylene, EPDM, neoprene, melamine, specialty foams) into precision foam parts using water jet cutting, die cutting, contour cutting, CNC routing, foam lamination, and compression molding. Serves OEM customers across automotive, medical, consumer goods, industrial, packaging, furniture, bedding, and military markets.
• Molded Urethane Foam Products Molded urethane foam products manufactured via injection molding for applications requiring consistent material properties and precision dimensions. Sold to OEM customers across automotive, medical, and industrial markets.
• Reticulated Foam Applicators Custom reticulated foam applicators designed for precise wicking and liquid retention, manufactured for cosmetics and personal-care applications such as tanning lotion products. Produced on custom-designed machinery at scale.
• Hybrid Vehicle Battery Thermal Management Products Foam separators and thermal management solutions for hybrid and electric vehicle battery packs, designed to maintain optimal cell temperature ranges and apply consistent pressure on cooling fins. Targets automotive OEMs.
• Filtration Foam Products

Quantifiable outcome

• 100,000 parts per week production rate achieved
• +4 more outcomes

Named customers2 records

Segments7 records

Ideal customer profiles2 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature7 records

Partnerships

Seven partnerships are on record, tiered core and subsidiary.

• BASFcoreStrategic or Co-development PartnerBASF is a materials supplier providing Basotect melamine-based foam, which Rogers Foam works with as part of their specialty foam offerings for applications requiring temperature resistance up to 300 degrees Fahrenheit.
• Rogers CorporationcoreStrategic or Co-development PartnerRogers Corporation supplies cast urethane Poron and silicone Bisco materials that Rogers Foam fabricates into custom parts for various industrial applications.
• Amcon FoamsubsidiaryOthersSubsidiary company of Rogers Foam located in Minneapolis, MN and Longmont, CO. Part of Rogers Foam's expanded geographic footprint and application knowledge.
• Vahala FoamsubsidiaryOthersSubsidiary company of Rogers Foam located in Elkhart, IN. Part of Rogers Foam's expanded geographic footprint and application knowledge.
• Capitol FoamsubsidiaryOthersSubsidiary company of Rogers Foam (capitolfoamproducts.com). Part of Rogers Foam's expanded geographic footprint and application knowledge.
• Cutters FoamsubsidiaryOthersSubsidiary company of Rogers Foam located in Elkhart, IN. Part of Rogers Foam's expanded geographic footprint and application knowledge.
• Foam Fabricators of MinnesotasubsidiaryOthersSubsidiary company of Rogers Foam located in Maple Lake, MN. Part of Rogers Foam's expanded geographic footprint and application knowledge.

Scale indicators7 records

Recent moves1 record

Expansion highlights6 records

Direct peers

• UFP Technologies: UFP Technologies is a public custom converter of engineered foams, plastics, and specialty materials serving medical, automotive, aerospace, and industrial OEMs — directly comparable in business model, customer base, and value-added fabrication focus to Rogers Foam.
• Future Foam Inc. Future Foam is a large U.S. manufacturer of polyurethane foam for furniture, bedding, and specialty applications — a direct peer in polyurethane foam fabrication and conversion with comparable customer base in bedding and furniture.
• Woodbridge Group: Woodbridge is a leading North American foam fabricator focused on automotive seating, NVH, and interior systems — directly comparable to Rogers' automotive foam business and contract manufacturing operations with similar tier-1 OEM customers.

Broad incumbents

• Sealed Air Corporation: Sealed Air is a global protective and food packaging manufacturer whose foam-in-place and fabricated foam packaging solutions overlap with Rogers' protective foam and specialty packaging segments.
• FXI (formerly Foamex International): FXI is one of the largest U.S. producers and converters of polyurethane and specialty foams for bedding, furniture, healthcare, and industrial markets — overlapping with Rogers' polyurethane fabrication, bedding/furniture, and filtration offerings at much larger scale.
• Recticel: Recticel is a Belgian-based global polyurethane foam manufacturer serving automotive, bedding, and industrial markets — a broader international incumbent whose engineered foams and fabricated parts overlap with Rogers' specialty offerings.
• Leggett & Platt: Leggett & Platt is a diversified manufacturer of engineered components including bedding foams, furniture cushioning, and automotive comfort products — broadly comparable to Rogers' bedding/furniture and automotive foam business lines.
• Carpenter Co. Carpenter Co. is the largest U.S. manufacturer of polyurethane foam and a major producer of specialty foam products for bedding, furniture, and automotive — a broad incumbent with significant overlap in urethane foam fabrication and automotive cushioning markets.

Others

• Sonoco Products Company: Sonoco is a global packaging conglomerate with protective foam packaging, custom molded packaging, and contract manufacturing capabilities — adjacent to Rogers' specialty foam packaging and contract manufacturing services.

Emerging players

• Pregis LLC: Pregis is a major producer of protective packaging including foam-based case inserts and cushioning solutions — comparable to Rogers' specialty packaging and military case insert business lines with similar end customers.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks7 records

Key highlights7 records

Customer concentration

• Facebookfacebook.com/rogers-foam-corporation-161614403857126
• LinkedInlinkedin.com/company/518121

Compliance10 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Subsidiaries4 records

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 Rogers Foam Corporation