Aerospace Foam Fabricator
For more than 50 years, Atlas Foam Products has been the trusted aerospace foam fabricator for leading OEMs and aerospace manufacturers. We engineer and fabricate foam materials and assemblies that comply with various MIL-SPEC standards including, FAR 25.853(a), PPP-C-1752, Airbus ABD 0031 — delivering flame-retardant aircraft interior components, precision-fit avionics packaging, and aerospace insulating foam solutions that protect critical components and reduce total cost.
Our Expertise in Aerospace Foam Packaging
The aerospace industry needs materials that go beyond ordinary packaging. Aerospace foams must withstand high-stress environments, absorb shock and vibration, and remain resilient across wide temperature ranges. They also need to comply with stringent flame-retardant standards such as FAR 25.853(a), PPP-C-1752, and Airbus ABD 0031, while maintaining the flexible properties required for aircraft interiors, electronics enclosures, and aerospace foam seals.
With our ability to design, Die Cut or hand fabricate Atlas Foam can meet most of your custom foam procurement needs.
Polyethylene Foam for Aerospace Applications
Polyethylene foam is one of the most widely used aerospace materials thanks to its durability, moisture resistance, and shock absorption properties. At Atlas Foam Products, we supply and fabricate multiple grades of polyethylene to meet exacting aerospace requirements, including FAR 25.853(a) and PPP-C-1752 MIL-SPEC compliance.
Ethafoam®
For packaging and cushioning applications that require both strength and longevity, Atlas Foam offers Ethafoam® formulations designed to perform under pressure:
- Lightweight, durable, and moisture-resistant, it's ideal for aerospace packaging applications that require reliable shock absorption and vibration dampening, especially when protecting heavier components, ideal for shock absorption, vibration dampening, and aerospace insulating foam applications.
Flame-Retardant Formulations
Our FAR 25.853 compliant flame-retardant polyethylene foam formulation:
- Provides enhanced safety: formulated with additives to meet stringent FAR 25.853 flame resistance standards, making them suitable for aircraft interiors.
- Primary applications: aircraft seating, aerospace upholstery foam, cushions, and resistance to compression set.
Properties
- Closed-Cell Structure: Delivers excellent water resistance, cushioning, and thermal insulation
- Chemical Resistance: Withstands fuels, oils, solvents, and a broad spectrum of aerospace chemicals
- Temperature Resistance: Performs from -40°C to 80°C
- Flexibility: Adapts to custom inserts, molded assemblies, and complex aerospace geometries
- Acoustic & Aerospace Thermal Insulation: Reduces in-cabin noise transmission and limits heat transfer for energy efficiency
Specifications
- Density: 1.8 to 9.0 lbs/ft³ (29 to 144 kg/m³)
- Flame Resistance: Ethafoam® FR 4101 meets FAR 25.853 (a) and Airbus ABD 0031 standards
- Temperature Range: -40° C to 80° C (-40° F to 176° F)
- Colors: Available in black, natural white, anti-static pink and blue,
Certifications
- Ethafoam® FR 4101: Complies with FAR 25.853 (a) and Airbus ABD 0031 directives for use in commercial aircraft interiors
- Ethafoam®: Meets A-A-59135 and A-A-59136 specifications
- MIL-SPEC Ethafoam®: Manufactured in accordance with PPP-C-1752 requirements
Polyurethane Foam
Atlas Foam Products also supplies the following types of polyurethane foam for aerospace foam applications:
- Polyether: Lightweight, flexible, good moisture resistance – ideal for cushioning and aerospace insulating foam applications, such as packaging sensitive electronics and instruments
- Polyester: Superior tensile strength and chemical resistance – ideal for applications requiring higher rigidity and impact resistance, such as long-term supportive and protective packaging
- Pyrell® Specialty Foam: Fire-retardant, sound-absorbing, impact-resistant – ideal for equipment-protective enclosures and aerospace upholstery foam components
Properties
- Lightweight: Reduces aircraft weight due to low density
- Chemical Resistance: Resistant to fuels, oils, solvents, and a wide range of other chemicals
- Temperature Resistance: Withstands -40°C to 80°C
- Flexibility: Flexible and conforming in various applications like including electronics cushioning
- Compression Set Resistance: Long-lasting performance under compression
- Acoustic Insulation: Improves passenger comfort by reducing noise transmission
- Thermal Insulation: Limits heat transfer to maintain cabin temperature and reduce energy consumption
Specifications Polyurethane Ester & Pyrell
- Density: 2.0 lbs/ft3 (32 kg/m3)
- Compression Set: Less than 10% at 50% deflection
- Flame Resistance: Pyrell® specialty foam meets FAR 25.853 flame resistance standards, PU Ester meets FMVSS302 & UL-94 HF-1
- Temperature Range: -40° C to 80° C (-40° F to 176° F)
- Colors: Charcoal
Certifications
- Pyrell Specialty Foam: Federal Standard FAR 25.853 (a) compliant for use in commercial aircraft interior compartment components
- PU Ester: MIL-PRF-26514 T1 C2 GC
Your Certified Aerospace Foam Supplier
Headquartered in Sylmar, California, Atlas Foam Products is a certified aerospace foam fabricator and supplier serving OEMs across the contiguous United States. Every project is backed by our proven compliance track record, rapid turnaround, and dedicated foam engineering team.
Contact Atlas Foam Products
Need a aerospace compliant foam solution? Atlas Foam Products' team of foam engineering experts is ready to help. Whether you need flame-retardant aircraft interior components, precision-fit avionics packaging, aerospace insulating foam, or MIL-SPEC cushioning materials — we deliver engineered solutions that meet your compliance requirements and timeline.
Call 818-514-5040 or fill out our online form to request a quote from an aerospace foam fabrication specialist today.
Have Questions?
Give us a call at 818-837-3626 or fill out the form to send a message to one of our Foam Experts. We proudly provide services to local areas including Los Angeles, San Fernando Valley, Santa Clarita Valley, Simi Valley, Ventura, Oxnard, Orange County, Riverside, San Bernardino, and the Contiguous U.S.
