Driven by precision: delivering high-performance foam solutions for Formula One
How Kewell Converters engineered bespoke automotive foam parts for a leading F1 racing team
Background
At Kewell Converters, we’re proud to be one of the UK’s most experienced foam fabricators and foam converters, delivering high-quality, precision-engineered foam solutions to a wide range of industries. With over 50 years of expertise in foam fabrication and foam conversion, our team thrives on solving complex challenges—especially in the fast-paced, high-stakes world of automotive engineering.
One of our most exciting recent projects involved supporting a Formula One racing team as they prepared for a major Grand Prix. The team approached us with a unique request: they needed custom-designed foam parts to securely house battery units used in their vehicles. The brief was clear but challenging—protect the components, maximise the number of units per case, and deliver the finished product within a tight deadline. Each order was different, requiring a fully bespoke solution and a high degree of collaboration across our team.
The challenge
In Formula One, there’s no margin for error. The customer needed tailored automotive foam inserts that would not only protect delicate battery units but also fit seamlessly into their standard transport boxes. These inserts had to be engineered to exact dimensions, use high-performance materials, and be produced quickly and efficiently.
With many variables and components to consider—including sizing, protection, material selection, and packaging—the challenge was not just technical but logistical. We also needed to ensure minimal waste while providing a premium finish and precise fit, reflecting the quality and performance expectations of a world-class racing team.
The solution
This project was a true team effort. Our skilled CAD designer kicked the project off by creating a concept drawing for a large plastic container. Within just a few days, the design was approved by the customer and then production was set into motion.
To meet the team’s performance and sustainability requirements, we chose Zotefoams for the project—specifically LDR 18 and Ecozote, a high-quality, recycled foam material. This selection aligned with the customer’s need for durability and environmental responsibility.
Once the material was in-house, our operations team comprising of John, Joel, Micky and Chris, worked together to bring the design to life. We used advanced water-jet cutting to shape the foam with high precision, followed by contour cutting and CNC routing to achieve complex profiles and clean edges. These techniques enabled us to deliver the highest standard of finish expected from a foam converter.
In just under 2 days of production time, the custom inserts were manufactured, assembled, and packed—ready to be shipped to the customer. We also took sustainability a step further by repurposing offcuts to create additional tray components, ensuring minimal waste and maximum value.
The results
The Formula One team was thrilled with the results. The finished foam parts met all requirements: the battery units were protected, the inserts fit their standard cases perfectly, and the maximum number of units could be transported efficiently.
The customer appreciated not only the quality of the foam parts but also the collaborative and responsive service from our team. Our ability to move quickly from concept to production—without compromising on quality—was critical to the success of the project.
This project demonstrates our expertise in automotive foam, our ability to work under pressure, and our commitment to delivering tailored, high-performance foam solutions that meet our customers’ unique needs.
Looking for expert automotive foam solutions?
Whether you’re in motorsport, EV development, or automotive logistics, Kewell Converters is your trusted partner for bespoke foam solutions. From water-jet cutting and CNC routing to premium Zotefoams and branded foams, we engineer every detail to meet the exacting demands of the automotive industry.
Visit our Automotive page to learn more and see how we can support your next project and don’t hesitate to get in touch with our team!
