Custom Foam Converting & Fabrication with 2D & 3D Foam Components
Forest City Technologies combines automated cutting, forming, molding, machining, laminating, and assembly to create lightweight foam products—from precision gaskets and pads to complex three-dimensional components and integrated systems.
Custom foam conversion is often associated with flat gaskets, pads, or packaging inserts. Forest City Technologies ‘capabilities extend beyond those typical applications. By combining precision converting with three-dimensional forming, molding, machining, joining, surface finishing, adhesive integration, and assembly, Forest City Technologies can support functional lightweight products with complex geometry and multiple performance requirements.
The process begins with the application: What must the component seal, protect, insulate, cushion, route, support, or reduce in weight? Forest City Technologies then evaluates material form, geometry, tolerance, production volume, attachment method, and downstream assembly to establish a practical manufacturing path.
Manufacturing Capabilities
- Two-dimensional conversion: Skiving, die cutting, flash cutting, waterjet cutting, laser cutting, and related profile-cutting methods.
- Three-dimensional fabrication: Thermoforming, vacuum forming, compression forming, injection molding, and five-axis machining.
- Laminating and adhesive integration: Multi-layer constructions and pressure-sensitive adhesive application.
- Joining and finishing: Welding, bonding, painting, and other secondary processes where applicable.
- Assembly: Multiple converted or fabricated elements combined into a more complete, production-ready component.
- Automated production: Purpose-built equipment and process controls developed around repeatability, throughput, and component handling.
Applications Beyond the Typical
- Complex ducts, plenums, housings, covers, sleeves, and flexible components
- Lightweight structural or semi-structural product elements
- Thermal, acoustic, vibration, cushioning, and impact-management components
- Seals and insulation with three-dimensional geometry
- Protective components for sensitive equipment and assemblies
- Finished products combining foam, plastic, adhesive, metal, or other materials
As part of the Forest City family of businesses, Forest City Technologies can draw on complementary foam engineering and fabrication knowledge from Technifab when an application requires deeper support in lightweight materials, complex three-dimensional foam structures, or specialized conversion methods.