Super Foam Corp
Super Foam Corp manufactures custom protective parts from a patented microcellular polyurea elastomer, offering nearly 2x the energy absorption of traditional foams while being 100% PFAS-free. The company casts parts to customer CAD files on its own automated production line, with samples shipping in 2 business days and a minimum order of one part.
- New Materials
- Chemical Technology
- Defense Tech
- Manufacturing / Industry 4.0
- Hardware
Funding
Funding not disclosed
Founders
Founder details are not available yet.
Product
Problem
Traditional protective foams degrade rapidly under repeated impacts, leach harmful PFAS "forever chemicals," and rely heavily on overseas supply chains that create unpredictability and bottlenecks. These material limitations force engineers and procurement teams to compromise between protection performance, safety compliance, and supply chain reliability.
Solution
Super Foam Corp manufactures ultra-high-performance polymer materials built on patented technology and produced through a proprietary automated process engineered to absorb maximum kinetic energy. The company's foam matrix delivers nearly 2x the energy absorption of traditional foams at 71.7 kJ/m³ while maintaining less than 20% load-bearing loss after seven impacts and 98% volumetric recovery from 25 m/s projectile impacts. The material is 100% PFAS-free and toxic-free, enabling regulatory compliance without sacrificing performance. The company offers a compact, fully automated manufacturing platform that can be deployed at a customer's own facility, reducing lead times and eliminating tariff exposure from overseas sourcing. Super Foam Corp serves multiple verticals including defense and tactical, automotive and aerospace, heavy-duty safety and sport, stationary storage and data centers, and mobile and portable power applications.
Target Audience
Primary customers include defense contractors and military suppliers, automotive and aerospace manufacturers, industrial safety equipment producers, and energy storage system integrators requiring high-performance impact protection materials.
Features
- Patented polyurea material chemistry delivering 71.7 kJ/m³ energy absorption, nearly 2x conventional foams
- 98% volumetric recovery after 25 m/s projectile impact and <20% load-bearing loss after 7 impacts, enabling reusable protection
- 100% PFAS-free and eco-pure chemical profile exceeding regulatory requirements
- Material is -12% lighter and +30% stiffer than traditional foams, optimizing payload and speed
- Fully automated, U.S.-based manufacturing with a compact "Factory In A Box" deployment platform installable at customer facilities
- Verified performance against military specifications for blast mitigation, body armor backing, and vehicle hull lining
- Cold-pour overmolding process ensures parts match the mold exactly, with even cell structure and repeatable dimensions
- Custom formulations with tested additives including graphene, biocide, and fire retardant, built into the formula rather than coated on
- Free FEA simulation session with an engineer before ordering, with samples typically $65 to $300 and a 2-business-day lead time