Custom Foam Fabrication Solutions in Philadelphia, Pennsylvania
Philadelphia, Pennsylvania, remains one of the Mid-Atlantic’s most diverse manufacturing centers, supported by strong commercial furniture, bedding, and materials industries. The region’s concentration of contract furniture producers, mattress manufacturers, and institutional suppliers drives consistent demand for precision-cut foam components that deliver comfort, durability, and design flexibility. Secondary industries in the area—such as medical packaging and distribution—also rely on engineered foam for cushioning and protection during transit.
Located within a short service radius from our Derry, Pennsylvania headquarters, Keystone Foam supports furniture and bedding manufacturers across Eastern Pennsylvania and Southern New Jersey. Our CNC contouring, laminating, and water-jet fabrication capabilities produce consistent, high-volume results tailored to the specific performance and comfort requirements of each application.
Contract Furniture & Upholstery Manufacturing
Philadelphia’s commercial and institutional furniture industry depends on reliable foam components that balance comfort, resilience, and form. Keystone Foam produces high-quality polyurethane, rebond, and viscoelastic foams used in seating, cushions, and back supports for offices, hospitality, and healthcare environments. Our precision cutting and profiling systems deliver consistent shapes and densities across large production runs—helping regional manufacturers maintain design accuracy and comfort standards.
Bedding & Comfort Layer Manufacturing
Eastern Pennsylvania is home to a strong network of mattress and bedding manufacturers, serving both branded and private-label markets. Keystone Foam provides flexible polyurethane, latex, and viscoelastic memory foams in multi-layer comfort builds for toppers, cores, and support layers. Our material expertise ensures the right balance of softness, durability, and breathability—enhancing end-user comfort while meeting production efficiency goals.
Advanced Foam Materials & Fabrication
Foam Material Type
- Polyurethane (PU) – Open and closed cell
- Polyethylene (PE) – Crosslinked and non-crosslinked
- EVA foam – Various densities
- Neoprene – Weather and chemical resistant
- Viscoelastic memory foam
Latex foam – Natural and synthetic - Expanded Polystyrene (EPS)
Precision Fabrication Services
- CNC contouring and cutting
- Die cutting and punching
- Water-jet cutting
- Heat sealing and welding
- Laminating and bonding
- Custom molding
- Precision profiling
Keystone Certifications:
AIB International Certified – 2025
Industry Material Compliance:
ISO 9001:2015
FDA CFR 21 177.1520 compliant materials
Mil-Spec testing and certification
UL 94-HFI flame-retardant standards
Safety Standards
- California Proposition 65 compliance
- Cal 117 fire-safety standards
- MVSS302 automotive standards
- OEKO-TEX certified materials available
Keystone Foam’s Derry headquarters is approximately 260 miles from Philadelphia, ensuring efficient shipping and regional supply coverage for manufacturers across Eastern Pennsylvania.
Polyurethane, viscoelastic, and rebond foams are most common for seating, cushions, and upholstered surfaces.
Yes. We provide PU, latex, and visco foams in custom-layered builds for mattress and topper production.
Yes. We offer Cal 117 and UL 94-HFI compliant materials to meet fire-safety and performance standards.
Yes, we support Amish craftsmen and other custom furniture makers, providing flexible minimums, fast prototyping, and precision contouring for limited runs and specialty projects.
Yes. Our CNC contouring and laminating systems allow high-volume production of consistent shapes and densities across thousands of parts.
Yes. Keystone Foam provides custom-layered foam builds combining PU, latex, and viscoelastic materials for comfort, durability, and breathability.
We primarily support the region’s furniture, bedding, and packaging manufacturers, delivering precision-cut foam components tailored for comfort, structure, and protection.
