Polymer Foam Market Report 2025

The polymer foam market size has grown strongly in recent years. It will grow from $112.76 billion in 2024 to $119.2 billion in 2025 at a compound annual growth rate (CAGR) of 5.7%. The growth in the historic period can be attributed to growth in construction and building industry, consumer electronics demand, expansion of aerospace industry, increasing use in furniture and bedding, medical and healthcare applications.

The polymer foam market size is expected to see strong growth in the next few years. It will grow to $151.91 billion in 2029 at a compound annual growth rate (CAGR) of 6.2%. The growth in the forecast period can be attributed to urbanization in developing regions, renewable and biodegradable polymer foams, focus on disaster-resilient construction, demand for high-performance insulation, energy efficiency initiatives. Major trends in the forecast period include advancements in polymer foam technologies, innovation in flexible foam products, integration of nanotechnology, customized solutions for end-use industries, smart packaging solutions.

The expansion of building and construction activities is anticipated to drive the growth of the polymer foam market in the future. Building and construction encompass the manufacturing and trade associated with the building, repairing, renovating, and maintaining of infrastructures. This sector involves the construction of buildings and the assembly of various infrastructures at different sites. Polymers are utilized as insulation, roofing, and sealant materials in this industry, contributing to air sealing and insulation while enhancing a building's strength. Therefore, an increase in building and construction activities is expected to boost market growth. For instance, the Office for National Statistics (ONS), a non-ministerial department in the UK, reported that annual new construction orders rose by 11.4% in 2022 compared to 2021, reaching a historic high of £80.837 billion ($102.16 billion). Thus, the growth of building and construction activities is driving the polymer foam market.

The rising sales of wood furniture are expected to fuel the growth of the polymer foam market in the future. Wood furniture includes room furnishings such as tables, chairs, wood flooring, cabinets (for kitchens, bathrooms, and vanities), and other covered furniture made from wood, wood composites, or manufactured wood materials. Polymer foam, particularly polyurethane foam, is used in wood furniture as an alternative to natural wood to replicate its appearance. This foam is created from a combination of polyol and isocyanate and is available in various densities to achieve different levels of hardness and durability. For example, in 2022, the Furniture Industry Research Association, a UK-based non-profit organization, reported that the UK furniture and furnishings sector achieved a manufacturing turnover of £11.35 billion ($14.8 billion), representing a 9.2% increase from the previous year. Consequently, the increasing sales of wood furniture are driving the growth of the polymer foam market.

Product innovations are a significant trend gaining traction in the polymer foam market. Leading companies in this sector are concentrating on developing new programmable and expandable polymer foams, including products made from electron beam cross-linking and recycled materials, to enhance their market position. For instance, in October 2023, Covestro and Selena, a construction chemicals manufacturer based in Poland, introduced bio-attributed polyurethane (PU) foams specifically designed for thermal insulation applications. These innovative foams are produced using renewable raw materials, which help decrease the carbon footprint associated with traditional insulation products. The new bio-attributed PU foams provide excellent thermal performance, contributing to improved energy efficiency in buildings.

Major companies in the polymer foam market are concentrating on introducing eco-friendly solutions to adopt sustainable practices, such as the mass balance approach, in order to gain a competitive advantage. The mass balance approach is a technique used across various industries, including chemicals, plastics, and food, to monitor the flow of sustainable materials through a complex value chain. For example, in September 2024, BASF, a Germany-based chemical company, and Future Foam, a U.S.-based manufacturer of various polyurethane foams, announced a partnership to launch the first commercially available flexible foam bedding made entirely from domestically produced BMB Lupranate T 80 TDI. This innovative foam marks a significant advancement towards sustainable manufacturing in the bedding industry by utilizing locally sourced materials, thereby reducing the environmental impact associated with traditional foam production. The collaboration highlights both companies' commitment to promoting eco-friendly practices while providing high-quality products that cater to consumer demand for sustainable bedding solutions.

In September 2023, Covestro, a Germany-based provider of high-performance materials, teamed up with the Selena Group to develop innovative solutions, including advanced foam products intended for construction and insulation applications. By combining their expertise and resources, Covestro and Selena Group aim to enhance their product offerings and bolster their market position within the construction industry. The Selena Group is a well-known manufacturer of construction chemicals and materials based in Poland.

Major companies operating in the polymer foam market include Sealed Air Corporation, Arkema Group, Armacell International SA, Borealis AG, Polymer Technologies Inc, Zotefoams plc, Synthos S A, BASF SE, KANEKA CORPORATION, Toray Industries Inc, Saudi Basic Industries Corporation, Huntsman International LLC, SEKISUI ALVEO AG, Covestro AG, Koepp Schaum GmbH, JSP Corporation, Lanxess AG, Tosoh Corporation, Recticel NV, Rogers Corporation, Woodbridge Foam Corporation, Trelleborg AB, Honeywell International Inc., Spongex, Genesys Aero systems.

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

Polymer foam refers to a polymer material characterized by the presence of numerous tiny foam holes within the polymer matrix, resulting in a porous structure. These materials typically exhibit lower density and offer good sound and heat insulation properties. Polymer foam is commonly used as insulation material in various industries.

The main types of polymer foams include polyurethane foam, polystyrene foam, PVC foam, phenolic foam, polyolefin foam, melamine foam, and others. Polystyrene foam is a synthetic polymer with thermoplastic properties, derived from the petroleum-based monomer known as styrene. It is available in both flexible and rigid foam forms and finds applications in diverse industries such as packaging, building and construction, furniture and bedding, automotive, rail, wind, marine, and others.

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The polymer foam market consists of sales of thermoplastic and thermoset foams, phenolformaldehyde and urea-formaldehyde foams. 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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