Sports & Leisure
Engineered foam solutions for protection, performance, and reliability
At Kewell Converters, our 50 years of foam expertise extends into the sport and leisure sector, where safety, comfort, and durability are critical. From impact-resistant padding and protective gear to lightweight inserts and thermal foams, we design and manufacture solutions that keep people safe, extend product life, and improve performance.
We specialise solely in foam conversion and fabrication. With an in-house engineering team and full CAD design support, we transform the properties of specialist foams, including Plastazote®, Evazote® Supazote®, Ecozote®, and ZOTEK®, into precisely engineered products that reduce supplier complexity and deliver long-term value.
Bespoke foam solutions for sports and leisure equipment
We supply custom foam parts, shapes, and inserts that meet exacting requirements for protection, weight reduction, and comfort. Applications include:
- Protective sports gear – lightweight yet high-density foams for helmets, cricket pads, shoulder guards, racing chest plates, and goalkeeper protection. Our foams absorb impact energy while remaining flexible and comfortable.
- Playground & outdoor equipment – UV-resistant, non-toxic foams ensure long-lasting durability and safety in all weather conditions
- Leisure and lifestyle products – from camping mats and backpacks to buoyant swimming aids, we design foams that are lightweight, water-resistant, and built to last
- Sports orthotics & supports – closed-cell foams that combine softness and rigidity to deliver comfort, performance, and resilience in prosthetic inserts, limb supports, and protective padding
High-performance foam materials that add value
Our customers in sport and leisure rely on foams that do more than cushion. The specialty foams we use are engineered for consistency, safety, and performance:
- Impact absorption – reducing injury risk by dissipating energy in high-impact sports
- Lightweight & durable – lowering material weight without sacrificing strength, improving usability and product longevity
- Water resistance & buoyancy – perfect for swimming aids and outdoor gear
- Thermal insulation – protecting users from heat and cold in extreme environments
- Lamination flexibility – foams can be combined with fabrics, plastics, carbon fibre, or honeycomb cores for enhanced performance
By offering precise foam fabrication methods such as CNC routing, water jet cutting, die cutting, and thermoforming, Kewell Converters ensures every component is optimised for manufacturing efficiency and quality.
Why procurement teams choose Kewell Converters
- 50 years of foam-only expertise – unrivalled knowledge of foam materials and how to get the best from them
- Independent and specialist – stockists of leading branded foams including Zotefoams’ AZOTE®, and ZOTEK® range, Palziv’s Palfoam and Galfoam, plus many others.
- Engineering-led approach – CAD design, prototyping, and production optimisation reduce risk, rework, and costs
- Supply chain simplification – we source, design, and manufacture in-house, reducing the need for multiple suppliers
- Bespoke solutions – we add value by creating engineered foam products
When safety, comfort, and compliance matter, procurement and quality managers trust Kewell Converters to deliver reliable foam solutions that perform in the toughest conditions.
Take the next step
If you’re developing protective foam solutions for sports, leisure, or outdoor applications, talk to the experts who have been engineering foam for over 50 years.
Get in touch with Kewell Converters today to discuss your project requirements.
FAQs
We work with branded foams such as AZOTE®, Plastazote®, Evazote® and ZOTEK®, chosen for their impact resistance, comfort, and durability.
Yes. Using CNC routing, water jet cutting, and thermoforming, we manufacture everything from helmet liners to Euro container inserts with precision.
They’re lighter, safer, and more durable than traditional materials, helping reduce injury risk, extend product life, and meet compliance standards.
No. Unlike resellers, we focus on engineered foam solutions – designed, fabricated, and optimised for your application.
