| Company Name | Year Established | |
| 1 | BASF SE | 1865 |
| 2 | Wanhua Chemical | 1998 |
| 3 | Covestro | 2015 |
| 4 | Huntsman Corporation | 1970 |
| 5 | FPC | 1962 |
| 6 | FSI | 1972 |
| 7 | General Plastics | 1941 |
With the continuous emergence of high-end precision instruments, valuable equipment, and premium handicrafts, the demand for polyurethane foam as a cushioning packaging or padding material has been steadily increasing.
In this vast and fiercely competitive global market, polyurethane foam manufacturers must possess exceptional innovation, consistent quality, and genuine global influence to stand out.
This article will introduce 7 leading polyurethane foam manufacturers in the world, exploring how they leverage superior craftsmanship, environmental commitment, and customer-centric solutions to drive the polyurethane foam industry and shape its future development.
1.BASF SE
Year Established:1865
Employee Size:11,2000
Business Capabilities:Chemical Manufacturing
Address:Carl-Bosch-Strasse 38, 67056 Ludwigshafen am Rhein, Germany
Website:https://www.basf.com/
Company Profile：
Since 1865, BASF SE has grown into the world’s largest chemical company, with operations in over 80 countries and approximately 360 production sites, serving industries such as automotive, construction, agriculture, and consumer goods.
BASF has strong competence and a broad product portfolio in both polyurethane raw materials (e.g. MDI, TDI, polyols) and polyurethane systems and foams.
Its innovative products such as “COMFORT FOAM” spray foam and “Autofroth” rigid foam are known for their high quality and energy-saving performance.
Driven by innovation, BASF develops eco-friendly foams with reduced volatile organic compound (VOC) emissions and renewable raw materials, aligning with global sustainability trends.
With its global supply chain, cutting-edge research and development, and customer-centric solutions, BASF SE is recognized as one of the world’s top polyurethane foam manufacturers.
2.Wanhua Chemical Group Co., Ltd
Year Established:1998
Employee Size:29000
Business Capabilities:Chemical Manufacturing
Address: No. 7, South Xingfu Road,Yantai, Shandong 264002, China
Website:https://en.whchem.com/
Company Profile：
Wanhua Chemical Group Co., Ltd., a global leader in China’s polyurethane industry, is one of the world’s largest MDI producers.
With an annual MDI capacity exceeding 3 million tons from its Yantai, Ningbo, and Hungary plants, Wanhua ensures a stable supply chain and cost advantages as a top manufacturer of polyurethane foam.
Its national R&D center drives innovation in low-VOC foams, bio-based polyols, and HFC-free rigid foams, widely used in refrigeration.
Using advanced foam molding, Wanhua tailors foam density (10 kg/m³ to over 200 kg/m³) and hardness for products like soft packaging pads and strong structural parts.
Serving construction, automotive, furniture, refrigeration, and packaging industries, Wanhua delivers efficient, eco-friendly foam solutions globally.
3.Covestro
Year Established:2015
Employee Size:17500
Business Capabilities:Chemical Manufacturing
Address:Kaiser-Wilhelm-Allee 60, 51373 Leverkusen, Germany
Website:https://www.covestro.com/en/
Company Profile：
Established in 2015 as a spin-off from Bayer’s material science division, Covestro has rapidly become a global frontrunner in the polyurethane foam industry, headquartered in Leverkusen, Germany.
With operations in over 30 countries and around 50 production sites worldwide, the company serves diverse sectors, including automotive, construction, electronics, and consumer goods. Covestro’s polyurethane foam offerings include high-resilience flexible foams for seating and mattresses, and rigid foams for energy-efficient insulation, addressing the growing demand for protective packaging for precision instruments and high-value products.
A pioneer in sustainability, Covestro develops circular economy solutions, such as foams made from recycled plastics and renewable raw materials, reducing environmental impact while maintaining performance.
Its innovation-driven approach, global supply chain, and commitment to customer collaboration position Covestro as a trusted polyurethane foam manufacturer.
4.Huntsman Corporation
Year Established:1970
Employee Size:6000
Business Capabilities:Polyurethane Product
Address: 10003 Woodloch Forest Drive, The Woodlands, TX 77380
Website:https://www.huntsman.com/
Company Profile：
Huntsman Corporation is a global chemical manufacturing company with four core business segments: polyurethanes, performance products, advanced materials, and textile effects, with its polyurethane segment being a key strength.
As one of the world’s leading polyurethane foam manufacturers, Huntsman produces and sells a range of polyurethane chemicals, including MDI , polyols, aniline, thermoplastic polyurethane (TPU), propylene oxide (PO), and methyl tert-butyl ether (MTBE). These chemicals are used to create flexible and rigid foams for applications in automotive seating, furniture mattresses, building insulation, and precision packaging.
Leveraging advanced molding and spray foam technologies, Huntsman delivers customized products, from high-resilience cushions to high-strength insulation panels, meeting diverse global customer needs.
Huntsman is committed to reducing the environmental impact of polyurethane foam, developing recyclable foams and low-emission formulations, such as its TEROL® polyols, which utilize recycled plastics and bio-based materials to lower carbon footprints.
Supported by global R&D centers and production networks, Huntsman drives innovation and efficiency, solidifying its position as a leading polyurethane foam manufacturer.
5.Foam Products Corporation
Year Established:1962
Employee Size:Unknown
Business Capabilities:Foam Product
Address: 2525 Adie Road, St. Louis, Missouri, America
Website:https://www.fpcfoam.com/
Company Profile：
Foam Products Corporation (FPC), founded in 1962 in the United States, specializes in the manufacturing, processing, and distribution of polyurethane foam.
With decades of experience in the polyurethane foam industry, FPC holds a significant position in the global market, renowned for its high-quality products and customized services, catering to industries such as packaging, construction, automotive, flooring, and industrial applications.
FPC’s polyurethane foam manufacturing business encompasses two main categories: flexible foam and rigid foam. Among them, polyether-based flexible foam is soft and non-abrasive, ideal for precision item packaging, while polyester-based foam is tougher, suited for demanding environments.
Additionally, the company produces, manufactures, and sells a range of standard and custom foam products, capable of creating foam components with specific shapes, densities, and performance characteristics tailored to client needs.
Through advanced cutting and processing technologies, such as hot-wire cutting and CNC contouring, FPC delivers solutions ranging from simple foam sheets to complex molded foam components, meeting the comprehensive foam needs of businesses across the United States and worldwide.
6.Foam Supplies Inc
Year Established:1972
Employee Size:1368
Business Capabilities:Polyurethane Foam Systems
Address: 13389 Lakefront Drive,Earth City, MO 63045
Website:https://fsi.co/
Company Profile：
Founded in 1972, FSI is the largest independent polyurethane systems supplier in the United States, dedicated to leading the polyurethane research and development industry.
As a premier global polyurethane foam manufacturer, FSI is renowned for its innovative technologies and eco-friendly solutions, serving industries such as construction, automotive, refrigeration, packaging, and marine applications.
FSI has forged a long-term partnership with Graco to deliver comprehensive, one-stop services, encompassing the design and development of advanced foam manufacturing and dispensing equipment, as well as high-pressure systems.
These include Graco’s Reactor series and FSI’s Onsite ACT™ systems, integrated with FSI’s Ecomate® fluorine-free blowing agent technology, ensuring efficient production and high-performance foams for applications ranging from spray insulation to molded packaging.
Through this strategic collaboration, FSI not only enhances customer production efficiency but also advances sustainable foam solutions with zero global warming potential (GWP), further solidifying its leadership in the global polyurethane market.
7.General Plastics Manufacturing Company
Year Established:1941
Employee Size:170
Business Capabilities:Polyurethane Foam Sheet Stock
Address: 4910 Burlington Way, Tacoma, WA 98409
Website:https://www.generalplastics.com/
Company Profile：
General Plastics Manufacturing Company founded in 1941, is an industry-leading enterprise with over 80 years of history in polyurethane foam manufacturing.
As a globally renowned manufacturer of polyurethane foam, it is famous for its LAST-A-FOAM® brand product line, which encompasses flexible, semi-rigid, and rigid foams, serving multiple industries including aerospace, defense, construction, nuclear energy, marine, composites, and packaging.
Through unique chemical formulations and build-to-print capabilities, the company precisely controls foam density (ranging from 3 to 50 lb/ft³), cell structure, and surface quality to produce high-performance custom components, meeting the demands for precision packaging, prototyping, and complex structural parts.
Its LAST-A-FOAM® series offers a diverse range of densities and properties, capable of remaining stable in extreme environments (from temperatures as low as -100°F to as high as 400°F), making it suitable for a wide array of applications, from commercial aircraft interiors to nuclear material transport containers.
The company utilizes advanced CNC machining, molding, and vacuum forming technologies, combined with an FAA-certified flame testing laboratory, to ensure products meet stringent aerospace and military standards, contributing to green manufacturing.
Conclusion
These seven companies collectively form the leading vanguard of the global polyurethane foam manufacturing industry.
Among them are multinational chemical giants that control core raw materials and operate on a massive scale, as well as specialized manufacturers renowned for years of expertise in niche markets, delivering customized, high-quality products.
With their extensive product portfolios (encompassing flexible, rigid, and semi-rigid foams), robust technological innovation, globalized service networks, and deep engagement with key industries such as aerospace, automotive, construction, and packaging, these companies collectively set the highest standards for the industry.
As such, for individuals or organizations seeking high-quality polyurethane foam solutions, aiming to understand market dynamics, or searching for reliable suppliers, these seven companies undoubtedly serve as critical benchmarks and industry leaders.
| Design | Quality | Delivery time | Service | Price | |
| BASF SE | ●●●●● | ●●●●● | ●●●●● | ●●●●● | ★★★★ |
| Wanhua Chemical | ●●●●● | ●●●●● | ●●●●● | ●●●●● | ★★★★ |
| Covestro | ●●●●● | ●●●●● | ●●●● | ●●●● | ★★★★ |
| Huntsman Corporation | ●●●●● | ●●●●● | ●●●●● | ●●●●● | ★★★★ |
| FPC | ●●●● | ●●●● | ●●●● | ●●●● | ★★★ |
| FSI | ●●●● | ●●●● | ●●●● | ●●●● | ★★★ |
| General Plastics | ●●●● | ●●●●● | ●●●●● | ●●●● | ★★★★ |