Foam
Cushions

Aerofoam's high-resilient seat cushions with integrated fireblocking are built for commercial aviation programs where comfort, safety, and regulatory compliance are equally non-negotiable. Designed and engineered around state-of-the-art materials — including high-resilient comfort foams and lightweight closed-cell foams — our cushions deliver the flexibility to specify the right solution for every class of service without compromising on passenger comfort or program performance.

Every cushion geometry is developed through Aerofoam's proprietary AI ergonomic design suite — combining human subject pressure mapping data with accelerated lifecycle testing that simulates the full demands of in-service use. The result is optimized cushion geometry and foam density specifications that are validated before a single production cushion is built.

Each cushion is engineered to meet FAA and EASA flammability requirements, with the fireblock layer bonded directly to the cushion body — providing a reliable flame-retardant barrier that also serves as a durable substrate for labels, Velcro, and other seat components. The result is a cleaner construction, consistent shape retention, and in-service performance that holds up across the full life of the program.

Aerofoam's high-resilient graphite seat cushions are built around a proprietary foam technology that sets them apart from conventional aircraft seating materials. Our graphite-filled foams incorporate super-expanding graphite particles that, when exposed to flame, expand rapidly to form a dense char layer — creating their own fire barrier and eliminating the need for a separate fireblocking layer. The result is a simpler, lighter cushion construction that meets FAA and EASA flammability requirements including CS 25.853 without added weight or complexity.

We produce headrests, seat backs, and seat bottoms in our graphite foam platform, and offer two grades of graphite-infused slow-recovery foam — giving engineers the ability to tune comfort performance for each seating application. These memory foam grades can be used alone or in combination with our high-resilient graphite foams, allowing for layered cushion assemblies that balance pressure distribution, weight savings, and comfort across all classes of service.

Aerofoam designs and manufactures aircraft flotation cushions for commercial programs requiring overwater operation compliance. Each cushion is engineered to satisfy FAA flotation certification standards while delivering the same comfort passengers expect from a standard seat cushion — no compromise between safety performance and the in-flight experience.

Flotation cushions are available in custom shapes and configurations across all seating classes and aircraft types. Our engineering team works directly with airlines and seating OEMs to develop flotation solutions that meet exact specifications for size, weight, comfort, and regulatory compliance.

The Featherlite FCS Series is Aerofoam's proprietary line of ultra-lightweight aircraft seat cushions — purpose-built to deliver meaningful, quantifiable fuel savings and weight reduction for commercial aviation programs without sacrificing passenger comfort. Every cushion in the FCS Series meets FAA flammability requirements while contributing to measurable reductions in aircraft operating weight — directly supporting airline sustainability goals and long-term cost performance.

The result is straightforward: the comfort your passengers expect, and the weight performance your operation demands.

Aerofoam designs and manufactures crew and flight attendant seat cushions that set the standard for crew seating comfort in commercial aviation. These cushions are developed as fully custom specialty assemblies — engineered to meet the exact dimensional, weight, and performance requirements of each crew seat configuration while delivering a level of comfort that reflects our commitment to the men and women who spend the most time in the air.

Each assembly utilizes the latest generation of specialty foam materials, purpose-selected to provide maximum comfort within the unique constraints of low-profile crew seat designs.

Aerofoam crew rest mattresses are built using the most advanced comfort material technologies available in commercial aviation. Each assembly integrates cooling gel foams, graphite and graphene-based foam formulations, and graphite-infused memory foam — working together to deliver superior pressure relief, thermal regulation, and vibration isolation for crews resting on long-haul operations.

Every material is selected with crew health and cabin air quality in mind. We use CertiPUR registered foams and water-based adhesives throughout — reducing outgassing and supporting a cleaner, healthier rest environment. From initial design through production, each mattress is developed to meet exact aircraft configuration requirements while holding to the highest standard of crew rest performance.