Custom Design & Prototyping Solutions
At Keystone Foam, we don’t just fabricate foam—we engineer solutions. Whether you’re shipping delicate electronics, designing protective packaging, developing custom seating cushions or anything in between, our team brings your ideas to life with speed and precision.
We are your One Stop for all of your Soft Touch Foam Fabrication needs.
Why Work With Keystone Foam for Design & Engineering?
- Full Prototype Capabilities – Prototyping is a core part of our capabilities. From quick-turn samples to full CAD drawings, we provide the tools you need to validate your design.
- A La Carte Flexibility – Keystone engineers’, design, and validate your concept before production. Send us your product, a simple sketch, or just measurements—we’ll start working on a solution.
- Advanced 3D Scanning – Our in-house 3D scanner captures exact dimensions, creating layered CAD/DFX files that can be shared, modified, and fabricated with confidence.
- End-to-End Service – From discovery to delivery, we design, test, and refine protective foam solutions that keep your products safe and your customers satisfied.
How It Works
Send us your product, DFX file, or basic specs. We can use our hand-held scanning devices to turn solutions around accurately and quickly.
We’ll design a protective solution and provide a CAD/DFX file for your approval.
Test and confirm fit, function, and performance, request design/material revisions.
Establish budget, volume, MOQs, etc. before production
Ready to get started?
Industries We Serve
• Electronics
• Consumer Goods
• Automotive
• Industrial Parts
• Medical Devices
• Healthcare Packaging
• Seating, Cushioning
• Furniture Applications
Case Study: Impact-Absorbing Golf Simulator Backdrop
Our now customer came with a need both for consistently produced product to meet their high-end clients’ expectations. But also, with a desire for thought leadership to produce a more effective product for their clientele.
When a client in the sports and entertainment industry required a durable foam solution for a custom golf simulator, Keystone Foam engineered a one-of-a-kind solution that absorbed repeated golf ball impacts—without compromising performance or aesthetics.
- Challenge: Contain and reduce the force of direct golf ball strikes within a simulator enclosure.
- Solution: Custom-engineered foam backdrop designed for strength, durability, and energy absorption.
- Design Process: Collaboration included CAD modeling, material selection, and prototype testing.
- Results: Provided a solution that blended safety, performance, and client specifications. We were able to modify design and product type to provide improved performance at a cost savings to our customer.
Let's Shape Your Success Together
At Keystone Foam, design and prototyping aren’t add-ons—they’re at the core of how we deliver value. From CAD models to 3D scans to working prototypes, we partner with you at every stage to turn ideas into proven solutions.
