Flexible Foam Market Report 2025

The flexible foam market size has grown strongly in recent years. It will grow from $53.96 billion in 2024 to $57.58 billion in 2025 at a compound annual growth rate (CAGR) of 6.7%. The growth in the historic period can be attributed to demand from consumer electronics sector, expansion of packaging applications, shift towards comfortable furniture and bedding, expansion of automotive applications, demand for insulation in construction.

The flexible foam market size is expected to see strong growth in the next few years. It will grow to $77.4 billion in 2029 at a compound annual growth rate (CAGR) of 7.7%. The growth in the forecast period can be attributed to adoption of smart and functional foam solutions, increasing usage in packaging industries, rise in healthcare and medical applications, advancements in bio-based materials, emphasis on energy efficiency in construction. Major trends in the forecast period include lightweight and high-performance materials, focus on sustainability and eco-friendly solutions, innovation in comfort and ergonomics, advancements in insulation and energy efficiency, shift towards customization and specialization.

The rising demand for flexible foam across various industries is anticipated to accelerate the growth of the flexible foam market in the future. Flexible foam is a polymer or plastic derived from petroleum hydrocarbons and other organic chemicals linked by urethane bonds. It is utilized in numerous industrial applications due to its outstanding properties, lower raw material costs, and reliability. The increased application of flexible foam in end-user sectors contributes to the rising demand, thereby boosting the flexible foam market. For instance, in August 2024, Furnishing Idea, a UK-based online portal focused on the furnishing industry, reported that the production of flexible polyurethane foams in Europe increased by 1.8 percent in 2023 compared to 2022, reaching 1.38 million tons. Furthermore, Turkey emerged as the leading region for PU block foam production in Europe. Approximately 50% of the foam produced is used in upholstered furniture, 35% in bedding, 10% in transportation, and 5% in other applications, similar to the previous year. Thus, the growing demand for flexible foam from various industries is propelling the expansion of the flexible foam market.

The rising demand in the building and construction industry is projected to drive the growth of the flexible foam market in the future. This industry includes a broad spectrum of activities related to the planning, design, construction, and maintenance of structures, facilities, and infrastructure. Flexible foam is utilized in this sector for its thermal insulation, sound absorption, versatility, lightweight construction, sealing capabilities, comfort, and cost-effectiveness. For example, in November 2023, Atradius, a Netherlands-based provider of trade credit insurance and debt collection services, reported that global construction output is anticipated to grow by 3.2% in 2023. Specifically, residential construction is expected to rise by 1.1%, while non-residential output is projected to increase by 5%. Consequently, the growing demand within the building and construction industry is fueling the expansion of the flexible foam market.

Innovative products are a key trend gaining traction in the flexible foam market. Leading companies in this sector are concentrating on developing cutting-edge solutions to bolster their market position. For example, in April 2024, Huntsman International LLC, a US-based chemical manufacturing firm, introduced the SHOKLESS polyurethane foam system. This system provides lightweight and durable foam solutions aimed at preserving the structural integrity and thermal performance of electric vehicle (EV) batteries, offering options for use as moldable encapsulants in battery modules or packs. These systems ensure rapid processability, flexibility in application methods, and stable mechanical properties across a broad temperature range, thereby enhancing safety and efficiency for EV battery manufacturers.

Major companies in the flexible foam market are concentrating on innovative products like bio-attributed PU (Polyurethane) foams to boost their revenues. Bio-attributed PU foams are polyurethane foams made from renewable or bio-based raw materials, in contrast to traditional PU foams, which primarily rely on petroleum-based sources. For example, in September 2023, Covestro AG, a materials science company based in Germany, partnered with Selena Group to introduce bio-attributed PU foams. This new product maintains the same qualities as its fossil fuel counterparts, allowing clients to seamlessly integrate it into their existing operations without compromising on quality. Besides bio-attributed PU foam, Selena's foam portfolio also includes recovered PET materials and bio-based polyols. This new range of polyurethane foams is more environmentally friendly and enhances thermal insulation in buildings.

In January 2022, Sheela Group, the parent company of Joyce and an India-based manufacturer specializing in PU Foam, successfully acquired Interplasp. The financial specifics of the acquisition were not disclosed. This strategic move is poised to solidify the Group's standing as one of the globe's leading and highly successful foam production enterprises. The acquisition facilitates the exchange of expertise, resources, and innovations on a global scale for Sheela Group. Interplasp, a Europe-based manufacturer, specializes in flexible polyurethane foam production. Through this acquisition, Sheela Group gains access to Interplasp's capabilities, potentially enhancing its own expertise and expanding its global reach in the production of foam-based materials. This strategic alignment signifies Sheela Group's commitment to fostering innovation and leveraging synergies to further strengthen its position as a key player in the global foam production industry.

Major companies operating in the flexible foam market are Badische Anilin- und Soda-Fabrik SE, The Dow Chemical Company, Huntsman Corporation, Ube Industries Ltd., Recticel Flexible Foams nv, Zotefoams PLC, The Woodbridge Group of Companies, SEKISUI Alveo AG, Covestro AG, Rogers Corporation, JSP Foam Products Pte. Ltd., O.R.S.A. Foam Spa, Mitsui Chemicals Inc., Kaneka Corporation, Flexipol Foams Pvt. Ltd., Sealed Air Corporation, UFP Technologies Inc., Vita Group, Eurofoam Group GmbH, Armacell International S.A., INOAC Corporation, FXI Inc., Future Foam Inc., W.W. Carpenter Company, Foamcraft Inc., Foam Supplies Inc., Alanto Ltd., FoamPartner (Switzerland) AG, Grand Rapids Foam Technologies, Hira Industries LLC, Innovo Packaging Group LLC.

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

Flexible foam, a processed polymer derived from petroleum hydrocarbons and other organic compounds linked by urethane bonds, results from a chemical reaction between polyols and isocyanates. Its cellular structure enables compression and resilience, offering cushioning properties.

Among the primary types of flexible foam are polyurethane (PU) foam, polyethylene (PE) foam, polypropylene (PP) foam, ethylene-vinyl acetate (EVA), and other variants. Polyurethane (PU) foam, a synthetic polymer, is created by combining polyols and isocyanates with a blowing agent and an amine catalyst. These foams come in various densities including high, medium, and low and find application in furniture and upholstery, automotive, packaging, construction, consumer goods, and other industries.

The flexible foam market research report is one of a series of new reports that provides flexible foam market statistics, including flexible foam industry global market size, regional shares, competitors with a flexible foam market share, detailed flexible foam market segments, market trends and opportunities, and any further data you may need to thrive in the flexible foam industry. This flexible 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 flexible foam market consists of sales of open-cell polyurethane foam, closed-cell polyurethane foam, bio-based cross-linked polyethylene foam, and extruded polyethylene foam. 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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