Foam, defence and innovation: insights from DSEI 2025

Why materials like foam remain essential in the military and defence industry

Earlier this month, our MD attended DSEI 2025 at ExCeL London, one of the largest defence and security exhibitions in the world. With thousands of military and defence specialists, it was a fascinating day. The halls were filled with cutting-edge technology, international collaboration, and conversations about how best to protect people and equipment in complex environments.

As Nick Kewell, our Managing Director, observed:

“Foam may not take centre stage at events like DSEI, but it plays an unseen and vital role in defence. It quietly protects, cushions, and enables performance in ways that are easy to overlook, but impossible to replace.”

Key takeaways from DSEI

1. Protection at the core

One of the strongest messages throughout the exhibition was the focus on defence, not aggression. Much of the innovation we saw centred around protection, resilience, and safeguarding, whether through interception systems, secure communications, or protective equipment. Foam fits naturally into this story, offering impact-resistant and shock-absorbing solutions for military and defence equipment.

2. Materials innovation

Lightweight, high-performance materials are increasingly shaping the industry. Whether for body armour, vehicle interiors, or shelters, materials need to balance strength, thermal and chemical resistance, and efficiency. Specialist foams like Plastazote are already part of that balance, supporting both equipment and personnel.

3. Resilient supply chains

We also noted the emphasis on sovereign supply chains and accountability. Defence customers want suppliers who are traceable, reliable, and compliant. For us, being a JOSCAR-approved supplier is one way we help meet these expectations, giving reassurance to our military and defence partners.

4. New and diverse voices

Alongside the big defence contractors, there was a growing presence of SMEs and start-ups. Their creativity is shaping areas like mobility, surveillance, and personal protection. As an SME ourselves, we value seeing the diversity of ideas being recognised and supported.

5. Emerging technologies

Autonomous systems, robotics, and AI are no longer future concepts, they’re already embedded across land, air, and naval defence. While these systems capture attention, many of them rely on custom foam components to protect sensitive electronics, weapons, and payloads during transport and operation.

Where foam makes the difference

Foam isn’t always visible on an exhibition stand, but its role in the defence and military industry is critical. Our work with bespoke military foam packaging solutions, protective inserts, and high-performance foams continues to support the sector in ways such as:

• Protecting equipment: from protective foam for military cargo and transport cases to custom-made MoD-approved foam packaging for secure weapon transit
• Supporting people: specialist padding in vehicles, aircraft, and ejection seat systems, providing both comfort and safety
• Performing under pressure: thermal, chemical and high-temperature foams used in demanding environments
• Sustaining operations: reverse-engineered, small-batch components help keep legacy equipment in service
• Hidden resilience: in drones, robotics, and unmanned vehicles, foam safeguards electronics, optics, and payloads

As Nick reflected:

“Foam rarely makes the headlines, but its role is constant, protecting both people and technology where it matters most.”

Looking ahead

The defence and military industry is often seen as technology-driven, yet some of its most essential contributions come from materials. Foam may not be glamorous, but it is high-density, shock-absorbing, fire-retardant, and adaptable, making it a quiet enabler of safety, reliability, and resilience.

We continue to work with the UK and international military, defence contractors, and aerospace partners on projects where foam is critical but rarely visible.

If you’d like to discuss custom foam solutions for the military and defence industry – from bespoke protective packaging to engineered foam components, please get in touch with our team.