Polyurethane Foam Market Report 2025

The polyurethane foam market size has grown strongly in recent years. It will grow from $54.27 billion in 2024 to $58.04 billion in 2025 at a compound annual growth rate (CAGR) of 6.9%. The growth in the historic period can be attributed to construction industry growth, automotive interior applications, furniture manufacturing, refrigeration and appliances, and footwear industry demand.

The polyurethane foam market size is expected to see strong growth in the next few years. It will grow to $81.2 billion in 2029 at a compound annual growth rate (CAGR) of 8.8%. The growth in the forecast period can be attributed to renewable and bio-based polyurethane foams, increasing demand for lightweight materials, rising emphasis on thermal insulation, growth in healthcare applications, and e-commerce packaging needs. Major trends in the forecast period include innovation in composite materials, circular economy practices, smart insulation solutions, sustainable packaging innovations, and advanced comfort technologies in bedding.

The increasing demand for automotive vehicles is anticipated to drive the growth of the polyurethane foam market in the coming years. An automotive vehicle is defined as any self-propelled vehicle utilized for transportation on public roads or in various environments. Polyurethane foam is commonly used in car seats and upholstery due to its exceptional cushioning, comfort, and durability, creating a supportive and comfortable seating experience for both drivers and passengers. For example, in January 2024, MarkLines Co., Ltd., a Japan-based company specializing in automotive industry information, reported that U.S. light vehicle sales soared by 13% in December 2023, with a total of 1,454,597 units sold. This surge indicates strong demand, particularly for trucks and SUVs, which saw a 15.7% increase compared to December 2022. Overall, automotive sales for the entire year rose by 12.3%, totaling 15,608,386 units, highlighting a significant recovery in consumer interest across various vehicle segments. Therefore, the rising demand for automotive vehicles is fueling the growth of the polyurethane foam market.

The rise in construction activities is significantly contributing to the growth of the polyurethane foam market. Construction activities encompass the processes related to building, modifying, repairing, and maintaining structures, systems, or organizations. In the construction industry, polyurethane foam is extensively used as an insulating material due to its exceptional thermal insulation properties, making it a preferred choice for buildings and structures. For example, a 2022 report from the Bureau of Economic Analysis (BEA), a U.S.-based government organization that provides official macroeconomic and industry statistics, indicated that the size of the U.S. construction industry grew from $1.916 trillion in the first quarter of 2021 to $2.016 trillion in the first quarter of 2022. Thus, the increase in construction activities is driving demand in the polyurethane foam market.

Major players in the polyurethane market are concentrating on technological innovations, such as lightweight and durable polyurethane foam technologies specifically designed for potting and securing cells in electric vehicle (EV) batteries. These advanced materials are engineered to provide optimal support and protection for EV battery cells. For example, in April 2024, Huntsman Corporation, a U.S.-based manufacturer and marketer of chemical products for both consumers and industrial clients, launched a new series of lightweight and durable SHOKLESS polyurethane foam technologies aimed at potting and securing cells in EV batteries, offering enhanced thermal and structural protection. These innovations are intended to tackle industry challenges by providing flexible manufacturing options and robust performance, in response to the increasing demand for advanced solutions within the automotive sector.

Leading companies in the polyurethane foam market are pursuing a strategic partnership approach to foster a circular economy, allowing for the recycling of products back into their raw materials for reuse to meet sustainability goals. Strategic partnerships involve companies leveraging each other's strengths and resources to achieve mutual benefits and success. For instance, in May 2022, Mitsui Chemicals Inc., a Japanese chemical company, collaborated with Microwave Chemical Co. Ltd., a Japan-based provider of microwave processing services, to initiate a project aimed at recycling flexible polyurethane foam through microwave technology. This method, which employs PlaWave technology, decomposes foam more quickly and with lower energy consumption compared to traditional techniques. The initiative aims to generate raw materials from foam offcuts, such as those used in mattresses, while minimizing CO2 emissions and energy costs. Furthermore, the process can be powered by renewable energy, providing a more sustainable solution for chemical recycling.

In June 2022, William T. Burnett & Co., Inc., a US-based technical foam and nonwoven products manufacturing company, acquired Flex Foam. This acquisition is expected to be a significant milestone for Wm. T. Burnett, offering customers of Flex Foam access to an extensive selection of technical polyether and polyester foams and nonwoven products. Flex Foam, a US-based manufacturer of polyurethane foam and carpet cushions, contributes to the production of flooring, furniture, bedding, and various automotive applications.

Major companies operating in the polyurethane foam market include BASF SE, Dow Inc., Saint-Gobain S.A., Wanhua Chemical Group Co Ltd, Covestro AG, DuPont de Nemours Inc., Sekisui Chemical Co. Ltd., Huntsman Corporation, Lanxess AG, Nitto Denko Corporation, Carpenter Co., FXI Holdings Inc., Woodbridge Foam Corporation, JSP Corporation, Rogers Corporation, Armacell International S.A., Future Foam Inc., Reciticel N.V., UFP Technologies Inc., FoamPartner Group, Greiner Perfoam GmbH, Zotefoams PLC, Foamcraft Inc., Eurofoam GmbH, Synthesia Internacional SL, American Excelsior Company, General Plastics Manufacturing Co., Innocor Inc.

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

Polyurethane foam, a synthetic or man-made polymer containing urethane radicals, is utilized for insulating buildings and protecting materials from elemental factors that can lead to corrosion. This type of foam serves as padding for a diverse array of consumer and industrial products, including beds, furniture, automobile interiors, carpet underlay, and packaging.

The primary categories of polyurethane foams include rigid foam, flexible foam, and spray foam. Rigid foam, a form of insulation known as continuous insulation, is applied to the exterior of buildings. Various processes involved in its production include slab stock foam, molded foam, lamination, and spraying, with distinct density compositions such as low-density, medium-density, and high-density compositions. These polyurethane foams find applications in various sectors, including bedding and furniture, transportation, packaging, automotive, construction, electronics, footwear, and other diverse applications.

The polyurethane foam market research report is one of a series of new reports that provides polyurethane foam market statistics, including polyurethane foam industry global market size, regional shares, competitors with a polyurethane foam market share, detailed polyurethane foam market segments, market trends and opportunities, and any further data you may need to thrive in the polyurethane foam industry. This polyurethane 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 polyurethane foam market consists of sales of mattresses, furniture, automobile interiors, carpet padding, and packaging. 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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