Foam engineered for life
What we do
Welcome to Kewell Converters, the UK’s leading specialist in foam fabrication and conversion. Established in 1971, we have over 50 years of experience in delivering bespoke, high-quality foam products tailored to meet the unique needs of our diverse clientele.
Industries we serve:
- Aerospace: Foam for cabin interiors, insulation panels, and lightweight components
- Defence & military: MOD-grade inserts, body armour, and equipment insulation
- Industrial engineering: Seals, gaskets, HVAC insulation, buoyancy foam and marine fenders
- Medical & healthcare: Prosthetics, orthopaedics, and comfort-focused device applications
- Transit & product packaging: Durable foam inserts and energy-absorbing, multi-use solutions
- Construction: Thermal insulation, soundproofing, and scaffold bumpers
Why choose Kewell Converters?
- Advanced CAD/CAM design and CNC precision manufacturing
- ISO 9001:2015 certified for impeccable quality
- Comprehensive selection of foam materials
- Certified partner of Zotefoams Plc
- Over 50 years of expertise in solving complex foam needs
- Independent ethical business offering a flexible service that delivers customised solutions
Contact Kewell Converters today to explore how we can support your custom foam requirements
We have been providing bespoke, quality, UK manufactured foam and a wide variety of applications since 1971.
We have relied on Kewell Converters to accurately translate quite complex drawings for more than a decade. We would recommend them for difficult work.
Quick turnaround of samples and advice on feasibility issues, quality of products supplied usually to the standard expected or above, and expectations met in terms of lead times.
Flexible with improving designs and working with sometimes inadequate files, quote turnaround time usually same day and good communication.
Manufacturing
Recognised as the foremost specialist in foam fabrication and conversion for batch production components within the UK, our profound expertise in manufacturing and design sets us apart.
Leveraging the prowess of advanced CAD/CAM design and programming, combined with precision-driven CNC multi-head/axis foam routing, we’re primed to deliver bespoke foam solutions.
At Kewell Converters, we use the latest in water jet cutting technology in our foam manufacturing process. This ensures sharp clean edges and a high-calibre result that isn’t possible with conventional press tools.
With foam moulding, the applications are almost endless. We’re able to deliver versatile solutions for numerous industry sectors from automotive and furniture manufacturing to window and door frames.
Materials
Kewell Converters stands as an esteemed independent distributor and accredited fabricator for Zotefoams. We proudly represent their range: Azote® (including Plastazote®, Evazote®, Supazote®, Ecozote ® and Propozote®) and Zotek® block foams. Our longstanding association ensures we can offer an extensive variety of foam grades, types, sizes, and thicknesses.
Industries
Since our inception, we’ve been at the forefront of delivering impeccable engineering, design, and manufacturing solutions in foam to a diverse spectrum of industries.
Family-run business
Established in 1971, Kewell Converters remains a family-owned and operated business. Our heritage is deeply embedded in our corporate ethos, and it shines through in every endeavour. Clients consistently appreciate our transparent approach, underscoring our commitment to openness and integrity. Our meticulous attention to detail, coupled with our design prowess, equips us to address even the most intricate design and fabrication challenges.
We are bespoke
At Kewell Converters, we excel in the design and manufacture of tailored foam products, aligning seamlessly with your specifications. Our core expertise lies in creating both bespoke and custom foam components, reflecting our unwavering commitment to precision and quality. Whether you provide us with hand-drawn sketches or CAD/CAM software outputs, we adeptly translate your visions into tangible solutions. Addressing design challenges ranging from straightforward to intricate, we ensure meticulous machining and fabrication, preparing foam products that are market-ready and up to industry standards.
We value quality
Quality isn’t just an aspiration—it’s a defining ethos for us. Our exemplary track record in design and manufacturing is manifested by our esteemed blue-chip clientele, contributing significantly to our turnover. We cherish our heritage and are recognized within the foam converting industry for our unparalleled quality and technical prowess. Upholding the highest industry standards, we operate in strict adherence to the ISO 9001:2015 quality management system.
We are excellent at precision
Specialising in high-tolerance foam fabrication and products, Kewell Converters stands at the pinnacle of foam expertise. Backed by a dedicated design team and years of manufacturing acumen, we are adeptly positioned to partner with you. Whether addressing challenges in performance, durability, or economic efficiency, we craft high-performance foam solutions tailored to consistently deliver on the specific requirements of your processes and applications.
Sustainability at the forefront
Our unwavering dedication to environmental stewardship and the principle of long-term sustainability is evident in every facet of our operation. We conscientiously strive to reduce our environmental footprint, ensuring a balance between our business endeavours and the greater good. We innovate in product design and manufacturing techniques to boost yields, ensuring the meticulous reduction of scrap and offcut processing. Through these endeavours, we are not only advancing our industry but also safeguarding our planet’s future.
Innovation is in our DNA
We’re curious and good at problem solving, continuing to push boundaries using new techniques and materials. We never stand still and invest in new technologies.
Integrity matters
We do what we say and are trustworthy and honest – ethics matter.
18th March 2025
Kewell Converters and the defence sector: Developing custom military foam solutions
Developing custom military foam solutions
Read more >
17th March 2025
Micky’s Journey: Balancing the factory and office at Kewell Converters
Behind the scenes as Production Supervisor
Read more >
6th March 2025
Empowering women in manufacturing: Kewell Converters celebrates International Women’s Day
Empowering women in manufacturing: Kewell Converters celebrates International Women’s Day
Read more >
