Coastal Automotive, LLC

What Coastal Automotive, LLC does

Coastal Automotive, LLC is a privately held Tier 1 automotive supplier specializing in engineered energy management foam products for vehicle passive safety. Founded in 2007 (originally as Vericorr Fabricating) and acquired in 2008 by family-owned Holland, Michigan-based holding company Coastal Group, the company operates a sales and engineering world headquarters in Rochester Hills, MI and manufacturing headquarters in Holland, MI, with global reach across North America, Mexico, Europe, and Asia.

The company's product platform comprises three proprietary foam families: IMPAXX extruded polystyrene (XPS) energy management foam, manufactured exclusively by Coastal under a long-term partnership with Dow Automotive established in 2010; TereSorb, a 2024 launch of recycled-PET sustainable energy absorption foam in four grades; and SDR Utility Foam, a microcellular polyethylene foam approved under FMVSS226 for airbag deployment assist. These materials are converted into finished components through in-house capabilities including CNC wire cutting, forming and molding, additive manufacturing, and Computer-Aided Engineering (CAE) simulation specializing in head-impact safety. Customers include at least 14 major automotive OEMs (General Motors, Toyota, Volkswagen, Ford, Tesla, BMW, Audi, Honda, Stellantis, Hyundai, KIA, Lucid, Lamborghini, Koenigsegg), NASCAR, and adjacent motorsports, heavy truck, marine, and aftermarket segments.

Coastal generates revenue through two streams: hardware sales of proprietary foam components to OEMs and Tier 1 suppliers, and contract manufacturing services (CNC cutting, forming/molding, assembly) for customer-specific components. The no-tooling manufacturing approach, IATF 16949 certification across all four facilities, and a track record of GM Supplier of the Year awards (2013, 2016, 2018) and five consecutive GM Supplier Quality Excellence Awards (2016-2020) anchor its position in regulated automotive safety supply chains. Current scale is approximately 100-125 employees across Michigan facilities, with no venture or private equity capital raised.

Name

Coastal Automotive, LLC

Legal name

Coastal Automotive

Website

https://coastal-automotive.com

Company type

Private

Founded year

2007

Operating status

Operating

Headcount range

101–250 employees

Short description

Coastal Automotive is a Tier 1 automotive supplier manufacturing proprietary energy management foam products (IMPAXX, TereSorb, SDR) for vehicle safety. Founded 2007 and based in Michigan, the company serves major automotive OEMs, NASCAR, and adjacent sectors via direct OEM supply and contract manufacturing.

Ownership category

akta.pro rank

Product category

Automotive Safety Components

NAICS

Polystyrene Foam Product Manufacturing (326140), Urethane and Other Foam Product (except Polystyrene) Manufacturing (32615)

SIC

Plastics Foam Products (3086)

akta.pro primary industry

Extruded Polystyrene (XPS) Foam Manufacturing (IMANAIAB)

akta.pro secondary industries

Foam Conversion & Fabrication (Cutting, Laminating, CNC, Packaging Inserts) (IMANAIAJ), Polyethylene (PE) Foam Manufacturing (IMANAIAE), Foam Protective Packaging (EPS/EPE/EPP, PU, Molded Foam) (IMALAFAA)

Keywords

• Automotive safety materials
• Energy management foam
• Passenger impact absorption
• Automotive component manufacturing
• CNC foam fabrication

Headquarters

HQ city

Rochester Hills

HQ country

United States

HQ region

North America

Offices3 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. Energy Management Foam Products: Sale of proprietary foam products including IMPAXX, TereSorb, and SDR Utility Foam to automotive OEMs and Tier 1 suppliers for use in passenger safety applications such as headliners, bumpers, seating, and headrests.
2. Contract Manufacturing Services: Manufacturing services including CNC wire cutting, forming/molding, and assembly services for customer-specific foam components. No-tooling manufacturing approach enables rapid development and production.

Go-to-market motion1 record

Distribution channels1 record

Marketing channels5 records

Core offering

Coastal Automotive manufactures proprietary energy management foam materials (IMPAXX™ extruded polystyrene foam, TereSorb™ recycled PET foam, and SDR Utility Foam) used in passive safety applications across automotive interiors such as headliners, bumpers, headrests, doors, and seating systems. The company also provides precision manufacturing services (CNC wire cutting, forming and molding, additive manufacturing) and engineering services (computer-aided engineering and product development) to automotive OEMs and Tier 1 suppliers globally.

Product overview

Coastal Automotive, LLC is a Tier 1 global automotive supplier specializing in passive safety and energy management solutions. The company offers a portfolio of engineered foam materials (IMPAXX™, TereSorb™, SDR Utility Foam) combined with advanced manufacturing capabilities (CNC wire cutting, forming & molding, additive manufacturing) and engineering services (CAE, product development). IMPAXX™ provides extruded polystyrene foam for energy absorption with up to 91% weight reduction; TereSorb™ offers sustainable recycled PET alternatives in multiple grades; and SDR Utility Foam addresses rapid deployment applications. These materials are processed through precision CNC cutting and forming/molding capabilities, supported by in-house CAE simulation and rapid product development services. The company serves automotive OEMs, Tier 1 suppliers, and motorsports (notably NASCAR) with a focus on passenger safety, weight reduction for EV applications, and sustainable manufacturing.

Differentiator

Problem solved

Functional benefit

Products and services

• IMPAXX™ Highly engineered extruded polystyrene (XPS) foam providing world-class energy absorption performance for automotive passive safety applications. Used in headliners, doors, headrests, instrument panels, bumpers, and seating systems; delivers up to 91% weight reduction and over 90% energy absorption efficiency.
• TereSorb™ Sustainable energy absorption material made from 100% recycled polyethylene terephthalate (PET), available in four grades (550, 900, 1050, 1800) with higher compressive strengths. Offers exceptional thermal stability, fast-loading energy absorption, and zero fogging with low VOCs; reduces carbon footprint by 37% versus virgin PET foam.
• SDR Utility Foam Multi-use microcellular polyethylene foam for Support/Deflect/Rebound rapid-deployment applications, including FMVSS226-approved side airbag directional deploy-assist, bumper stability, AC duct support, garnish reinforcements, and headliner filler. Up to 90% lighter than extruded metal and 70% lighter than extruded plastic.
• CNC Wire Cutting Services Precision computer-controlled 2D and 3D material cutting service for foam components with state-of-the-art vision systems. Design changes can be implemented in CAD within minutes with physical parts delivered within hours, eliminating tooling requirements.
• Computer-Aided Engineering (CAE) Services CAE engineering services with 18+ years of expertise in head-impact safety and interior analysis for the automotive industry. Includes head impact simulation, buckling analysis, product failure simulation, and static load analysis using OEM-preferred software.
• Product Development Services Full-cycle product development from concept to prototype to production in six phases: Concept Development & Ideation, CAD Design and Engineering, CAE Modeling & Testing, Prototype Development, Lab Testing, and Production & Delivery, using agile processes for rapid turnaround.
• Forming & Molding Services Forming and molding manufacturing services including cold forming for complex curvatures without heat, vacuum forming for rapid component development, die cutting for versatile customization, and compression molding for lightweight composite multi-material solutions.

Quantifiable outcome

• Up to 91% weight reduction compared to competing energy absorption materials
• +5 more outcomes

Named customers15 records

Segments5 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature6 records

Partnerships

Six partnerships are on record, tiered core and minor.

• Sealed AircoreStrategic or Co-development Partner · 1 January 2011Collaborative license agreement to manufacture components using foam with unique properties for airbag deployment, complementing the IMPAXX product line and establishing Coastal Automotive as a world leader in foam-based safety products.
• Dow AutomotivecoreStrategic or Co-development Partner · 1 January 2010Long-term partnership established in 2010 transitioning Coastal Automotive from contract manufacturer to full-service provider and exclusive manufacturer for IMPAXX energy absorbing products. Became direct supplier to OEMs and all major Tier 1 suppliers through this partnership.
• Automation Alley - Project DIAMOnDcoreStrategic or Co-development PartnerParticipation in Project DIAMOnD (Distributed, Independent, Agile Manufacturing on Demand) providing 3D printing capabilities for PPE production and prototyping. Project organized by Automation Alley and funded by Oakland and Macomb counties through federal grants.
• University of Michigan - IOE ProgramminorStrategic or Co-development PartnerPartnership with University of Michigan Industrial and Operations Engineering program for senior design projects providing real-world learning opportunities for students.
• Motor & Equipment Manufacturers Association (MEMA)coreGTM or Marketing PartnerActive participation in MEMA advocacy efforts including Legislative Summit in Washington D.C. addressing policy issues affecting automotive industry including R&D tax credits and workforce development.
• Recycling PartnerscoreOthersPartnership with recycling companies to collect and process 100% of unusable foam or scrap from manufacturing. Recycled material used to make polystyrene-based products including insulation boards for construction.

Scale indicators5 records

Recent moves9 records

Expansion highlights6 records

Direct peers

• JSP Corporation: Japanese manufacturer of expanded polypropylene (EPP) and other polymeric foams widely used for automotive energy management and packaging. Direct competitor to Coastal's IMPAXX in head-impact, seating, and bumper applications across global OEMs.
• Woodbridge Group: Major Tier 1 supplier of foam and trim systems to automotive OEMs, with deep penetration in seating, headrest, and interior energy management. Competes with Coastal for OEM foam-content programs globally.
• Recticel: European polyurethane and specialty foam producer with a dedicated automotive segment serving seating, interior trim, and acoustic/energy management. Closely comparable in foam chemistry and OEM customer base to Coastal's SDR and TereSorb lines.
• Zotefoams: Manufacturer of cross-linked polyolefin and other high-performance specialty foams used in automotive, aerospace, and industrial energy absorption. Comparable in offering engineered, low-density foam solutions to similar industrial/OEM customers.
• Armacell: Global manufacturer of engineered foams (including PET-based ArmaPET and PU-based products) for industrial and automotive applications including energy absorption. Comparable in technology platform and end-market exposure.

Broad incumbents

• Faurecia (FORVIA): One of the world's largest automotive Tier 1 suppliers, with seating, interiors, and clean mobility divisions that consume significant volumes of foam. Competes with Coastal indirectly as a full-system interior supplier to the same global OEMs.
• Magna International: Global automotive mega-supplier with seating, body, and powertrain capabilities, including proprietary foam and energy-management content. Represents the scale competitor Coastal would face if an OEM elects to consolidate foam sourcing with a full-system supplier.
• Lear Corporation: Major Tier 1 seating and electrical systems supplier with substantial proprietary foam content in seats and headrests. Competes with Coastal for headrest and seating-related foam programs.
• BASF: Largest chemicals producer, supplying polyurethane foam systems and engineered plastics used for automotive energy management and interior components. Competes with Coastal's IMPAXX/SDR as an incumbent materials supplier to OEMs.

Others

• Sonoco: Diversified packaging manufacturer with protective foam and molded pulp offerings serving industrial and consumer goods logistics. Adjacent rather than directly competing — protective packaging rather than automotive interior foam — but shares the engineered-foam processing technology base.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat6 records

Key risks6 records

Key highlights7 records

Customer concentration

• Instagraminstagram.com/coastalautomotive
• LinkedInlinkedin.com/company/coastal-automotive-llc

Compliance5 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles10 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 Coastal Automotive, LLC