Consumer Foam Market Report 2025

The consumer foam market size has grown strongly in recent years. It will grow from $41.47 billion in 2024 to $44.33 billion in 2025 at a compound annual growth rate (CAGR) of 6.9%. The growth in the historic period can be attributed to foam material science advancements, acoustic insulation requirement, flexible foam packaging evolution, sports and leisure industry demand, consumer preference for comfort products.

The consumer foam market size is expected to see strong growth in the next few years. It will grow to $59.54 billion in 2029 at a compound annual growth rate (CAGR) of 7.7%. The growth in the forecast period can be attributed to growing demand in furniture and bedding, expanding automotive sector, rise in construction industry, healthcare and medical applications, e-commerce impact. Major trends in the forecast period include regulatory compliance and standards, material science advancements, collaborations.

The consumer foam market is poised for growth, driven by the increasing demand for foam in the bedding and furniture industries. Bedding, a fundamental piece of furniture for sleeping, and the broader furniture industry are witnessing a surge in the popularity of foam mattresses. These mattresses are favored for their comfort, and recent market trends include products that allow consumers to customize foam layers based on their comfort preferences. Foam's utility extends to cushions and mattresses, providing durable and comfortable shapes to consumers. A notable statistic from August 2022 reveals a 20.5% growth in online mattress sales compared to 2021, emphasizing the rising need for foam in bedding and furniture, a trend set to propel the consumer foam market.

The consumer foam market is anticipated to experience growth propelled by the expanding automotive industry. Consumer foam plays a pivotal role in enhancing comfort and insulation within vehicle interiors, contributing to an improved driving experience and safety. Recent data from August 2023, sourced from the Board of Governors of the Federal Reserve System, highlights an increase in total vehicle production in the United States to 11.77 million units in July, up from 10.91 million units in June. This growth underscores the impact of the expanding automotive industry in driving the demand for consumer foam.

Major companies in the consumer foam market are developing innovative products, such as Pocketed Coil Technology, to improve comfort, support, and durability in foam-based mattresses and seating solutions. Pocketed Coil Technology, also referred to as individually wrapped coil technology, involves a mattress design in which each coil or spring is enclosed in its own fabric pocket. For example, in May 2024, Serta Simmons Bedding (SSB) LLC, a U.S.-based sleep company, introduced the Beauty Sleep collection. This mattress line is designed to offer quality sleep solutions and includes eight models featuring quilted innerspring and hybrid constructions. It incorporates Original Beautyrest Pocketed Coil® Technology to ensure consistent support and comfort using high-quality foams. Additionally, it features AllCool Gel memory foam, which adapts to the body's shape for improved pressure relief. The AirCool foam includes a specialized channeled structure that facilitates airflow through the mattress, promoting a cool and comfortable sleeping experience.

Major players in the consumer foam market are strategically focusing on temperature-controlled packaging solutions to gain a competitive edge. Temperature-controlled packaging solutions, designed to maintain precise temperature environments for packaged products, are becoming a focal point for companies seeking differentiation. A case in point is Cruz Foam, a US-based packaging company, introducing two eco-friendly packaging products, Cruz Wrap and Cruz Cool, in October 2023. These products, crafted from sustainable materials like upcycled shrimp shells and recyclable chitin foam, address the need for environmentally conscious packaging solutions.

In August 2024, Wynnchurch Capital LLC, a U.S.-based private equity firm, acquired Harbor Foam for an undisclosed amount. This acquisition is part of Wynnchurch Capital LLC's strategy to consolidate its foam-related investments under the brand Foam Holdings, also referred to as Alleguard, to better serve its customer base in the Midwest. Harbor Foam is a U.S.-based manufacturer of polystyrene and consumer foams.

Major companies operating in the consumer foam market are Covestro AG, ACH Foam Technologies LLC, Arkema Inc., BASF SE, Borealis AG, Dow Chemical Company, Hanwha Chemical Corporation, Huntsman Corporation, JSP Corporation, Kaneka Corporation, Loyalty Group Limited, Mitsui Chemicals Inc., Saudi Basic Industries Corporation, Compagnie de Saint-Gobain SA, Sekisui Chemical Co. Ltd., Toray Industries Inc., Trelleborg AB, Woodbridge Foam Corporation, INOAC Corporation, Recticel NV, Rogers Corporation, Foamcraft Inc., Henkel Ag & Co. Kgaa, UFP Technologies Inc., Armacell International S.A., Sealed Air Corporation, Zotefoams PLC, American Excelsior Company, All Foam Products Co. Inc., Wisconsin Foam Products Inc., ArtUSA Noise Control Products Inc.

Asia-Pacific was the largest region in the consumer foam market share in 2024. Asia-Pacific is expected to be the fastest-growing region in the forecast period. The regions covered in the consumer foam market report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East, Africa. The countries covered in the consumer foam market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

Consumer foam is a material characterized by numerous tiny air bubbles that create a frothy or thick substance. These foam cushions play a crucial role in various consumer and commercial applications, such as bedding, furniture, and automotive interiors. They offer effective protection and support for delicate items throughout the distribution chain.

The primary categories of consumer foams include flexible and rigid foam. Flexible foam is designed to provide cushioning for a diverse range of commercial and consumer products. This polymer possesses a cellular structure, demonstrating compression and resilience properties. It is manufactured through the reaction of polyols and isocyanates. The different types of resins involved in flexible foam production include polystyrene, polyurethane, phenolic, polyolefins, and others. Flexible foam finds applications in bedding and furniture, automotive, consumer electronics and appliances, footwear, sports and recreational products, as well as other areas such as beauty and personal care, apparel, and household cleaning.

The consumer foam market research report is one of a series of new reports that provides consumer foam market statistics, including consumer foam industry global market size, regional shares, competitors with a consumer foam market share, detailed consumer foam market segments, market trends and opportunities, and any further data you may need to thrive in the consumer foam industry. This consumer foam market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenario of the industry.

The consumer foam market consists of sales of foam that is used in furniture cushioning, bedding, carpet underlay, and mattresses. Values in this market are ‘factory gate’ values, that is, the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors, and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD, unless otherwise specified).

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

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