Aerospace & Aviation
Lightweight, fire-retardant, and engineered for flight-critical performance
For aerospace and aviation projects, every gram, every tolerance, and every material property matters. That’s why procurement and engineering teams trust Kewell Converters. With over 50 years of foam conversion expertise, we design and manufacture bespoke foam components that meet the strictest aerospace standards, delivering weight savings, safety compliance, and durable performance in the harshest environments.
At Kewell Converters, we work exclusively with foam. This singular expertise combined with our large in-house engineering team and full CAD design capability means we don’t just supply foam parts. We provide complete engineered foam solutions that reduce supplier complexity and add value at every stage.
Why aerospace procurement teams choose Kewell Converters
- Trusted expertise – five decades of exclusive foam conversion for aviation applications
- Compliance built in – components designed and manufactured to meet FAR/JAR 25.853 (App F Pt I) fire safety standards
- Material specialism – extensive experience with Zotefoams’ ZOTEK® and PLASTAZOTE® foams, including fire-retardant, conductive, and static dissipative grades
- Supply chain efficiency – we can source materials, design components, manage prototyping, and deliver finished parts, minimising supplier touchpoints
- Precision and repeatability – advanced CNC routing, lamination, welding, die-cutting, and fabrication ensure consistent quality across every production run
Bespoke foam components for aerospace applications
We supply custom foam parts across a wide range of aerospace and aviation requirements, including:
Airframe
Ducting, door and window gaskets, insulation panels, and cable harness protection
Cabin interiors
Seating pads, lightweight crash pads, buoyancy cushions, and ejection seat support
Thermal and acoustic insulation
ZOTEK® F foams engineered for ducts, linings, and airframes
Protective foam
Crash pads, headrests, and impact-resistant inserts for passenger safety
Packaging & tooling
Conductive foams for static-sensitive electronics, flight case inserts, and tool control solutions to eliminate FOD risk
Galley and cargo
Thermal insulation and foam components that withstand chemicals, vibration, and fluctuating temperatures
High-performance aerospace foam materials
Our specialty foams offer unique properties critical for aerospace:
- Ultra-lightweight options – such as PLASTAZOTE® MP15FR, the lightest closed-cell polyolefin foam available
- Flame-retardant grades – PLASTAZOTE® LD24FR and LD45FR, designed to meet fire safety regulations
- Conductive & static dissipative foams – LD32CN and LD30SD, protecting sensitive electronics from ESD damage
- Standard and high-density foams – LD33 and LD45, widely used for tool control and protective inserts in aviation and defence
- Moisture and chemical resistance – ensuring long-term reliability in demanding aircraft environments
Every grade is selected and optimised for its intended use, whether it’s lightweight cabin interiors, impact-absorbing safety pads, or durable tool storage inserts. Many of these foams are already approved by major aircraft OEMs giving procurement teams confidence in compliance and performance.
From concept to flight-ready components
Working with Kewell Converters means more than sourcing foam parts. It means:
- Design optimisation from day one with full CAD support
- Prototyping and testing to validate before production
- Scalable supply from one-off parts to volume manufacturing
Consistent, compliant results that meet aerospace regulations and procurement expectations
Partner with the aerospace foam experts
Whether you’re sourcing custom foam inserts for aircraft interiors, lightweight thermal insulation, or protective foam packaging for sensitive avionics, Kewell Converters delivers solutions that meet exacting aerospace standards.
Get in touch today to discuss your aerospace foam requirements with our specialist team.
FAQs
Yes. We supply flame-retardant foams such as PLASTAZOTE® MP15FR, LD24FR and LD45FR, which comply with FAR/JAR 25.853.
Absolutely. We provide custom foam solutions for civil aviation, defence contractors, and military applications.
Yes. We support everything from single prototypes to full-scale supply, ensuring compliance and performance before commitment.
We supply conductive and static dissipative foams (LD32CN, LD30SD) for safe packaging and storage of static-sensitive avionics and electronics.
Yes. We have an inhouse Quality Team and can offer FAI reporting in accordance with your inspection and compliance requirements.
