AeroFoams

Aerofoam's high-resilient foam materials are specialty comfort foams developed specifically for commercial aviation passenger seating. Engineered to deliver superior support and pressure distribution, our high-resilient foam line is formulated to maintain consistent performance throughout the full service life of the cushion — ensuring passengers experience the same level of comfort on every flight.

Our high-resilient foams incorporate lightweight material technologies that contribute to meaningful aircraft weight savings and support airline sustainability objectives — without compromising comfort or durability. Working closely with airlines and seating OEMs, our engineering team develops high-resilient foam solutions that meet FAA flammability requirements while delivering market-leading passenger comfort.

Aerofoam introduced graphite-filled foams to commercial aviation to deliver an unmatched level of passenger seating comfort. Our proprietary lightweight high-resilient graphite-filled foams are the result of extensive research and development — engineered to meet the strictest FAA and EASA safety and performance requirements while setting a new standard for comfort in commercial aviation seating.

The high-resilient properties of our graphite-filled foams allow cushions to be built with higher density at lower weight — improving passenger comfort while helping airlines reduce overall aircraft weight and fuel consumption. Graphite also increases thermal capacity, making the foam inherently flame retardant and capable of meeting FAA and EASA flammability standards including CS 25.853.

Aerofoam's graphite memory foams were developed to solve one of commercial aviation's most persistent comfort challenges — delivering the plush, pressure-relieving feel of heavy luxury foam materials in a lightweight aerospace-grade formulation. Purpose-built for commercial aviation seating, our proprietary graphite-infused memory foam replicates the sensation of much heavier luxury materials while meeting the strict weight, flammability, and durability requirements of modern airline interior programs.

The viscoelastic construction greatly reduces and relieves passenger pressure points — conforming to the body to distribute weight evenly and eliminate discomfort on long-haul flights. Combined with graphite infusion for enhanced thermal regulation and long-term shape retention, the result is a memory foam that feels like a premium luxury product — engineered to perform like an aerospace component.

In addition to our standard product offerings, Aerofoam provides custom foam solutions designed to meet the specific requirements of our customers. Our engineering team works closely with airlines and seat manufacturers to develop tailored foam products that address unique challenges and opportunities in commercial aviation.

Whether it's developing new foam formulations, creating custom shapes and sizes, or optimizing materials for specific performance characteristics, Aerofoam has the expertise and capabilities to deliver innovative foam solutions that enhance passenger comfort and meet the evolving needs of the aviation industry.

Aerofoam stocks and fabricates a comprehensive line of FAA and OSU-compliant specialty foam materials engineered for the full range of aircraft interior applications — from armrests and padded surrounds to vertical surfaces and everything in between. Our specialty foam portfolio includes Zotefoams and Zotek closed-cell foam materials, Ensolite foams, PVC/NBR foams, rigid polyurethane foams, and FR EPP and EPE foams.

Each material is selected and processed to meet the specific performance, weight, flammability, and OSU heat release requirements of its intended application. Our engineering team works closely with airlines, seating OEMs, and interior designers to identify the right foam solution for every component — providing a single, vertically integrated source for specialty foam materials across the full spectrum of commercial aviation interior programs.