Foam Design

A WORLD LEADER IN
FOAM FABRICATION &
CUSHION PACKAGING. CAPABILITIES STATEMENT & FEATURED PRODUCTS FOAM DEMANDS - AND REWARDS - PRECISION

1. A WORLD LEADER IN
FOAM FABRICATION AND
CUSHION PACKAGING.
IS0-9001:2008 AS9100C

2. FoamDesign.com [phone] 444 Transport Ct. Lexington, KY 40511
IS0-9001:2008
AS9100C
Foam Design, Inc. has been a world leader in foam fabrication for over 41 years.
As experts in foam packaging, we are able to analyze your product design and
requirements to create unique and innovative cushion packaging solutions
designed with the function, fragility and aesthetics of your product in mind.
Whether it’s packaging for the military, aerospace, automotive or electronics
industries, Foam Design can help you create a foam solution that satisfi es your
unique application.
To meet all of your diverse needs, Foam Design maintains a state of the art
manufacturing facility centrally located in Lexington, Kentucky. Staffed with an
award winning R&D and design team, we are proud of our ability to customize
foam solutions to meet your specifi c needs.
From the simplest foam cushion to the most complex, our engineers will
work with you to create precise, manufacturable, top-quality foam pieces that
fi t between this, that and within your budget.
Contact us today to see what Foam Design can do for you.
INC

3. SHAPING IDEAS INTO
AEROSPACE AND
DEFENSE SOLUTIONS.

4. FoamDesign.com [phone] 444 Transport Ct. Lexington, KY 40511
DEFENSE AND AEROSPACE
Foam Design specializes in designing and fabricating foam components used in
aerospace and munitions manufacturing. Every solution is customized by a level
of design, knowledge of materials and process expertise. Durable custom-molded
parts are manufactured from our fl ame-retardant, self-extinguishing, fl exible or
rigid polyurethane foams. From 5-axis routers to water-jet cutting and assembly,
Foam Design can provide your next solution.
CUSTOM PACKAGING
Munitions packaging from Foam Design is uniquely designed to cradle your
precious cargo. Whether you're shipping ordnance or delicate electronics
(or a bit of both), our military-spec foam hugs your parts, dampening vibration,
preventing jiggles, and insuring safe and secure delivery.

AVIATION PRODUCTS
Advanced composite aircraft depend on precision-manufactured foam pieces.
From fuel-tank protection to wing-stiffening and sound ablation, we build the
foam parts that support next-gen aerospace.
PRECISION PARTS
Our fabrication capabilities and design expertise provide
defense and aerospace customers with foam solutions
for mission-critical devices that require intricate parts
cut to precise tolerances.
INC
Our fabrication capabilities and design expertise provide
defense and aerospace customers with foam solutions
for mission-critical devices that require intricate parts
IS0-9001:2008 AS9100C

5. OIL ERASER IS UNLIKE
ANYTHING YOU’VE EVER
SEEN BEFORE.
THIS FOAM EATS OIL.

6. Oil Eraser is a new bio-based hydrophobic oleophilic foam that can absorb
80 times its own weight in petrochemicals.
​
It’s durable, re-usable, and suitable for a variety of environmental and
industrial applications. This seemingly impossible product could revolutionize
preservation and reclamation efforts.

Oil Eraser uses a proprietary eco-friendly solvent to release and reclaim
captured oil. Because this process minimizes mechanical wear, Oil Eraser
can be re-used uo to 200X.

Oil Eraser absorbs 80X it’s weight in: Crude Oil, Heavy Oil, Silicone Oil,
Light Oil, Octane, Chlorobenzene, Diesel Oil, Toluene, Chloroform
FoamDesign.com [phone] 444 Transport Ct. Lexington, KY 40511
IS0-9001:2008
AS9100C
TM
Crude Oil
Heavy Oil
Silicone Oil
Light Oil
Octane
Chlorobenzene
Diesel Oil
Toluene
Chloroform
0 2000 4000 6000 8000 10000
BioFoam coated with a
proprietary formulation.
Does not pick up water.
Coated Foam
Uncoated Foam

7. OUR BIOREACTOR MEDIA
IS UNLIKE ANY OTHER
BIOMEDIA.

8. FoamDesign.com [phone] 444 Transport Ct. Lexington, KY 40511
IS0-9001:2008 | AS9100C
FoamDesign.com [phone] 444 Transport Ct. Lexington, KY 40511
RETHINK WASTEWATER
Our biomedia is engineered to grow active biofi lms, for treating
organic contaminants and for nitrifi cation and denitrifi cation, as
in the case of ammonia treatment. This biomedia, unlike other
biomedias, is designed to create aerobic conditions on the
outside area of the biomedia to nitrify the ammonia to nitrate/
nitrite and anoxic conditions on the inside of the biomedia, in
order to denitrify the nitrate/nitrite to nitrogen gas. The biomedia
has a chemical coating on the surface of the foam material which
enables rapid attachment of the active biofi lms.
In typical uncoated biomedias, biofi lm attachment and growth can
take considerable time, while in our coated biomedias, full biofi lm growth is usually achieved in a few hours.
In addition, 10% of the media is supplied with biomass pellets that contain organisms (aerobic bacteria,
nitrifi ers/denitrifi ers), to seed the bed during start-up. This allows faster start-up of the biobeds, especially
since nitrifi ers and denitrifi ers are slow growing organisms. Furthermore, biofi lm attachment of these slow
growing organisms prevents washout, which is a common problem with suspended culture bioreactors. In
addition, the attached biofi lms increase active biomass concentrations in the biobeds fi ve to seven-fold over
suspended culture bioreactors, thereby increasing biotreatment rates substantially.
Another advantage of our biomedias is our ability to coat these
biomedias with super-oleophilic coatings that allow the media to
capture free and emulsifi ed oil in the wastewater. This prevents
the oil from fl oating to the surface of the bioreactor, allowing the
oil to stay immobilized on the biomedia surface, and immersed
within the bioreactor liquid, wherein it can be biodegraded
by the active bacteria. Unlike other foam biomedias that
simply fl oat on the surface, our biomedias are engineered to
be neutrally buoyant, thereby allowing them to stay within the
water and move around and rotate within the bioreactor liquid.
Furthermore, the foam used in our biomedia is stiff and protected
to prevent compression due to biofi lm weight, and is engineered
to allow water to fl ow through the biomedia, as it moves around
in the bioreactor liquid.

9. Federal Government System
for Award Management (SAM)
(WBENC) Certified
Woman-Owned Business
Certification Number
2005128756
NAICS Codes:
326150:
Urethane and other foam products
(except polystyrene)
326199:
All other plastics
product manufacturing.
DUNS: 07-132-4479
ITAR Registered Code M35304
Cage Code: 1T579
EIN: 61-0865119
Quality System: Perry Johnson
IS0-9001:2008 & AS9100C
Registration #C2015-00023
Awards
Boeing Performance
Excellence Award,
Orbital ATK Growth Supplier
Recognition Award for
Outstanding Performance
We offer business solutions for all facets of today’s ever changing
commercial and industrial landscape. From startups to established
industries, we relentlessly work to exceed your individual requirements.
We were founded in the early 70’s and have been converting foam and
surpassing our clients expectations for over 42 years.
Whether you are seeking a mass produced part or a product prototype,
we are up to the task. We have the facilities, the experience, and the
innovative minds to provide you with winning solutions. Foam Design has
been recognized over the years for outstanding quality and supplier
performance excellence. We are ready to offer you responsive customer
support and unmatched expertise in foam fabrication.
CAPABILITIES STATEMENT
Five-Axis Water Jet Cutting
Five-Axis Milling
Horizontal Wire Profile Cutting
Vertical Wire Profile Cutting
Die Cutting
Post Molding Cross-Linked PE
Foam Convoluting
RIM Urethane Molding
Reticulated PU Fabrication
Slitting and Skiving
Foam Tube Forming
Lamination – Heat/Adhesive
MANUFACTURING CAPABILITIES
0ffice: 859-231-7006 Foam Design.com Fax: [phone]
Reticulate Foams
Rigid Urethane Molding
Melamine Foam
HDPE
UHMW
100% Compostable Packing
Acoustical Foam
Water Filtration Foam
Petroleum Absorbing Foams
Rubber and Neoprene
FEATURED PRODUCTS
Ethafoam
Military Grade Ethafoam
Zotefoams
Crosslink (XLPE)
Plastic Corrugated
EPP
EPE
EPS
EVA
Urethane

10. A Woman Owned Small Business (WOSB)
Sustainability
0ffi ce: 859-231-7006 Foam Design.com Fax: [phone]
Protecting Our Environment
Foam Design supports the U.S. EPA’s waste management
hierarchy of reduce, reuse, recycle and recover.
Foam Design uses an Erema extruder to turn
scrap polyethylene (PE) into reprocessed plastic pellets.
Sustainability
Foam Design is partnering with its supply network to help
develop new markets and applications for Restore packaging,
the 100% renewable and compostable protective packaging –
powered by mushrooms. Every Restore product is
100% compostable providing a viable alternative to
traditional packaging disposal methods.