Flexible Foam Global Market Report 2026

Flexible foam, a processed polymer derived from petroleum hydrocarbons and other organic compounds linked by urethane bonds, results from a chemical reaction between polyols and isocyanates. Its cellular structure enables compression and resilience, offering cushioning properties.

Among the primary types of flexible foam are polyurethane (PU) foam, polyethylene (PE) foam, polypropylene (PP) foam, ethylene-vinyl acetate (EVA), and other variants. Polyurethane (PU) foam, a synthetic polymer, is created by combining polyols and isocyanates with a blowing agent and an amine catalyst. These foams come in various densities including high, medium, and low and find application in furniture and upholstery, automotive, packaging, construction, consumer goods, and other industries.

Note that the outlook for this market is being affected by rapid changes in trade relations and tariffs globally. The report will be updated prior to delivery to reflect the latest status, including revised forecasts and quantified impact analysis. The report's Recommendations and Conclusions sections will be updated to give strategies for entities dealing with the fast-moving international environment.

Tariffs are impacting the flexible foam market by increasing costs of imported polyols, isocyanates, additives, and foam processing machinery. Producers in North America and Europe are most affected due to reliance on imported chemical feedstocks, while Asia-Pacific faces pricing pressure on export-oriented foam products. These tariffs are raising production costs and affecting downstream pricing. However, they are also encouraging local sourcing of raw materials and innovation in bio-based and recyclable foam alternatives.

The flexible foam market research report is one of a series of new reports from The Business Research Company that provides flexible foam market statistics, including flexible foam industry global market size, regional shares, competitors with a flexible foam market share, detailed flexible foam market segments, market trends and opportunities, and any further data you may need to thrive in the flexible foam industry. This flexible foam market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenario of the industry.

The flexible foam market size has grown strongly in recent years. It will grow from $56.8 billion in 2025 to $61.09 billion in 2026 at a compound annual growth rate (CAGR) of 7.5%. The growth in the historic period can be attributed to expansion of furniture manufacturing, growth of automotive production, increasing demand for protective packaging, availability of polyurethane raw materials, rising consumer goods production.

The flexible foam market size is expected to see strong growth in the next few years. It will grow to $80.05 billion in 2030 at a compound annual growth rate (CAGR) of 7.0%. The growth in the forecast period can be attributed to increasing demand for eco-friendly foams, rising adoption in electric vehicles, expansion of construction insulation applications, growing focus on recyclable foam materials, increasing investments in advanced polymer technologies. Major trends in the forecast period include growing demand for lightweight cushioning materials, rising use in automotive interiors, expansion of sustainable foam formulations, increased adoption in packaging applications, enhanced comfort and durability optimization.

The growing demand for flexible foam from various industries is expected to boost the growth of the flexible foam market going forward. Flexible foam is a polymer or plastic produced from petroleum hydrocarbons and other organic chemicals joined by urethane bonds. It is used across several industrial applications due to its exceptional properties, lower raw material costs, and reliability. The increasing utilization of flexible foam in end-user industries drives higher demand, thereby supporting market growth. For instance, in August 2024, according to Furnishing Idea, a UK-based web portal for the furnishing industry, Europe's production of flexible polyurethane foams in 2023 rose by 1.8% compared to 2022, reaching 1.38 million tons. Turkey emerged as the largest PU block foam-producing region in Europe, with 50% of the foam used in upholstered furniture, 35% in bedding, 10% in transportation, and 5% in other applications, similar to the previous year. Therefore, rising demand from various industries is driving the flexible foam market.

Innovation is a key trend gaining traction in the flexible foam market. Major companies are developing advanced solutions to strengthen their market position. For instance, in April 2024, Huntsman International LLC, a US-based chemical manufacturing company, launched the SHOKLESS polyurethane foam system. This system provides lightweight, durable foam solutions designed to maintain the structural integrity and thermal performance of electric vehicle (EV) batteries, with options for use as moldable encapsulants in battery modules or packs. These systems offer fast processability, flexible application methods, and stable mechanical properties across a broad temperature range, ensuring improved safety and efficiency for EV battery manufacturers.

In June 2023, Carpenter Co., a US-based producer of comfort and specialty polymer products, acquired Recticel N.V.'s Engineered Foams Division for an undisclosed amount. This acquisition enables Carpenter to enhance its flexible foam portfolio and become the world's largest vertically integrated manufacturer of polyurethane foams and specialty polymer products. Recticel N.V.'s Engineered Foams Division is a Belgium-based provider of flexible polyurethane foam solutions for bedding, furniture, automotive seating, and other specialty applications.

Major companies operating in the flexible foam market are Badische Anilin- und Soda-Fabrik SE, The Dow Chemical Company, Huntsman Corporation, Ube Industries Ltd., Recticel Flexible Foams nv, Zotefoams PLC, The Woodbridge Group of Companies, SEKISUI Alveo AG, Covestro AG, Rogers Corporation, JSP Foam Products Pte. Ltd., O.R.S.A. Foam Spa, Mitsui Chemicals Inc., Kaneka Corporation, Flexipol Foams Pvt. Ltd., Sealed Air Corporation, UFP Technologies Inc., Vita Group, Eurofoam Group GmbH, Armacell International S.A., INOAC Corporation, FXI Inc., Future Foam Inc., W.W. Carpenter Company, Foamcraft Inc., Foam Supplies Inc., Alanto Ltd., FoamPartner (Switzerland) AG, Grand Rapids Foam Technologies, Hira Industries LLC, Innovo Packaging Group LLC

Asia-Pacific was the largest region in the flexible foam market share in 2025. The regions covered in the flexible foam market report are Asia-Pacific, South East Asia, Western Europe, Eastern Europe, North America, South America, Middle East, Africa

The countries covered in the flexible foam market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Taiwan, Russia, South Korea, UK, USA, Canada, Italy, Spain

The flexible foam market consists of sales of open-cell polyurethane foam, closed-cell polyurethane foam, bio-based cross-linked polyethylene foam, and extruded polyethylene foam. Values in this market are 'factory gate' values, that is the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors, and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD unless otherwise specified).

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

Flexible Foam Market Global Report 2026 from The Business Research Company provides strategists, marketers and senior management with the critical information they need to assess the market.

This report focuses flexible foam market which is experiencing strong growth. The report gives a guide to the trends which will be shaping the market over the next ten years and beyond.

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Where is the largest and fastest growing market for flexible foam ? How does the market relate to the overall economy, demography and other similar markets? What forces will shape the market going forward, including technological disruption, regulatory shifts, and changing consumer preferences? The flexible foam market global report from the Business Research Company answers all these questions and many more.

The report covers market characteristics, size and growth, segmentation, regional and country breakdowns, total addressable market (TAM), market attractiveness score (MAS), competitive landscape, market shares, company scoring matrix, trends and strategies for this market. It traces the market's historic and forecast market growth by geography.

• The market characteristics section of the report defines and explains the market. This section also examines key products and services offered in the market, evaluates brand-level differentiation, compares product features, and highlights major innovation and product development trends.
• The supply chain analysis section provides an overview of the entire value chain, including key raw materials, resources, and supplier analysis. It also provides a list competitor at each level of the supply chain.
• The updated trends and strategies section analyses the shape of the market as it evolves and highlights emerging technology trends such as digital transformation, automation, sustainability initiatives, and AI-driven innovation. It suggests how companies can leverage these advancements to strengthen their market position and achieve competitive differentiation.
• The regulatory and investment landscape section provides an overview of the key regulatory frameworks, regularity bodies, associations, and government policies influencing the market. It also examines major investment flows, incentives, and funding trends shaping industry growth and innovation.
• The market size section gives the market size ($b) covering both the historic growth of the market, and forecasting its development.
• The forecasts are made after considering the major factors currently impacting the market. These include the technological advancements such as AI and automation, Russia-Ukraine war, trade tariffs (government-imposed import/export duties), elevated inflation and interest rates.
• The total addressable market (TAM) analysis section defines and estimates the market potential compares it with the current market size, and provides strategic insights and growth opportunities based on this evaluation.
• The market attractiveness scoring section evaluates the market based on a quantitative scoring framework that considers growth potential, competitive dynamics, strategic fit, and risk profile. It also provides interpretive insights and strategic implications for decision-makers.
• Market segmentations break down the market into sub markets.
• The regional and country breakdowns section gives an analysis of the market in each geography and the size of the market by geography and compares their historic and forecast growth.
• Expanded geographical coverage includes Taiwan and Southeast Asia, reflecting recent supply chain realignments and manufacturing shifts in the region. This section analyzes how these markets are becoming increasingly important hubs in the global value chain.
• The competitive landscape chapter gives a description of the competitive nature of the market, market shares, and a description of the leading companies. Key financial deals which have shaped the market in recent years are identified.
• The company scoring matrix section evaluates and ranks leading companies based on a multi-parameter framework that includes market share or revenues, product innovation, and brand recognition.

Scope

• Markets Covered:1) By Type: Polyurethane (PU) Foam; Polyethylene (PE) Foam; Polypropylene (PP) Foam; Ethylene-Vinyl Acetate (EVA); Other Types
• 2) By Density: High-Density; Medium-Density; Low-Density
• 3) By Application: Furniture And Upholstery; Automotive; Packaging; Building And Construction; Consumer Goods; Other Applications
• Subsegments:
• 1) By Polyurethane (PU) Foam: Flexible PU Foam; Rigid PU Foam
• 2) By Polyethylene (PE) Foam: Cross-Linked PE Foam; Non-Cross-Linked PE Foam
• 3) By Polypropylene (PP) Foam: Expanded PP Foam; Extruded PP Foam
• 4) By Ethylene-Vinyl Acetate (EVA) Foam: Closed-Cell EVA Foam; Open-Cell EVA Foam
• 5) By Other Types: Neoprene Foam; Rubber Foam; Latex Foam
• Companies Mentioned: Badische Anilin- und Soda-Fabrik SE; The Dow Chemical Company; Huntsman Corporation; Ube Industries Ltd.; Recticel Flexible Foams nv; Zotefoams PLC; The Woodbridge Group of Companies; SEKISUI Alveo AG; Covestro AG; Rogers Corporation; JSP Foam Products Pte. Ltd.; O.R.S.A. Foam Spa; Mitsui Chemicals Inc.; Kaneka Corporation; Flexipol Foams Pvt. Ltd.; Sealed Air Corporation; UFP Technologies Inc.; Vita Group; Eurofoam Group GmbH; Armacell International S.A.; INOAC Corporation; FXI Inc.; Future Foam Inc.; W.W. Carpenter Company; Foamcraft Inc.; Foam Supplies Inc.; Alanto Ltd.; FoamPartner (Switzerland) AG; Grand Rapids Foam Technologies; Hira Industries LLC; Innovo Packaging Group LLC
• Countries: Australia; Brazil; China; France; Germany; India; Indonesia; Japan; Taiwan; Russia; South Korea; UK; USA; Canada; Italy; Spain
• Regions: Asia-Pacific; South East Asia; Western Europe; Eastern Europe; North America; South America; Middle East; Africa
• Time Series: Five years historic and ten years forecast.
• Data: Ratios of market size and growth to related markets, GDP proportions, expenditure per capita,
• Data Segmentations: country and regional historic and forecast data, market share of competitors, market segments.
• Sourcing and Referencing: Data and analysis throughout the report is sourced using end notes.
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