Polyurethane Foam Market Report 2026

The polyurethane foam market size has grown strongly in recent years. It will grow from $57.26 billion in 2025 to $62.02 billion in 2026 at a compound annual growth rate (CAGR) of 8.3%. The growth in the historic period can be attributed to growth of construction and housing projects, rising demand for furniture and bedding products, expansion of automotive interiors manufacturing, increasing use of insulation materials, availability of slabstock foam processes.

The polyurethane foam market size is expected to see strong growth in the next few years. It will grow to $86.17 billion in 2030 at a compound annual growth rate (CAGR) of 8.6%. The growth in the forecast period can be attributed to increasing investments in green building construction, rising demand for electric vehicle insulation materials, expansion of sustainable furniture production, growing adoption of spray insulation solutions, increasing focus on recyclable foam materials. Major trends in the forecast period include increasing demand for energy-efficient insulation materials, rising use in automotive lightweighting applications, growing adoption of spray foam insulation, expansion of high-performance flexible foams, enhanced focus on comfort and durability.

The rising demand for automotive vehicles is expected to drive the growth of the polyurethane foam market going forward. An automotive vehicle refers to any self-propelled vehicle used for transportation on public roads or in other settings. Polyurethane foam is widely used in car seats and upholstery due to its excellent cushioning, comfort, and durability, providing a supportive and comfortable seating experience for both drivers and passengers. For example, in January 2024, according to MarkLines Co., Ltd., a Japan-based company providing information on the automobile industry, U.S. light vehicle sales increased by 13% in December 2023, reaching 1,454,597 units, with strong demand particularly for trucks and SUVs, which rose 15.7% compared to December 2022. For the full year, automotive sales grew by 12.3%, totaling 15,608,386 units, reflecting a robust recovery in consumer interest across multiple vehicle segments. Thus, growing automotive demand is fueling 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.

In December 2023, Carpenter Co., a US-based polyurethane foam manufacturer, acquired the Engineered Foams business of Recticel SA/NV for approximately €450 million ($0.5 billion). Through this acquisition, Carpenter Co. aims to expand its engineered foam portfolio, strengthen its presence in specialty foam markets, enhance production capabilities, and drive long-term growth across North American and European operations. Recticel SA/NV, a Belgium-based company, specializes in high-performance polyurethane foam solutions for insulation, automotive, and industrial applications.

Major companies operating in the polyurethane foam market are BASF SE, Covestro AG, Huntsman Corporation, Dow Inc., Mitsui Chemicals, Inc., Recticel SA, Woodbridge Group, FXI Holdings, Inc., Sheela Foam Limited, Vita Group (The Vita Group), Carpenter Company, INOAC Corporation, Sekisui Chemical Co., Ltd., Armacell International S.A., UBE Corporation, Wanhua Chemical Group Co., Ltd., Saint-Gobain S.A., FoamPartner Group, Rogers Foam Corporation, Trelleborg AB.

Asia-Pacific was the largest region in the polyurethane foam market in 2025. 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, South East Asia, 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, Taiwan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

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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