Manufactured in the USA
Custom protective foam parts, built to your spec.
Tell us what the part has to survive and send your CAD. We formulate the foam, cast the part to your shape and size, check it in simulation and send you a sample. Every step happens in-house in the USA.
Up to 20 MB. All uploads are secure and confidential. Minimum order: one part.
- Manufactured in the USA
- Patented material, exclusive SDSU license
- PFAS-free chemistry
- FEA simulation before tooling
- Minimum order: one part
Parts made for teams at
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- Helicoid
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Fully custom
Everything about the part is yours to set.
A catalog foam comes in one density and one sheet thickness, and your design has to adapt to it. We start from your part instead.
Formulation
A foam chemistry tuned to your load case, not picked from a catalog.
Additives
Graphene, biocide or fire retardant, built into the formula instead of coated on.
Density and stiffness
About 100 to 355 kg/m³, set by how hard the hit is and how much load the part carries.
Shape
Any shape, cast to your CAD: solid, cored or lattice, molded around your hardware.
Size
Ambient cure with no ovens or autoclaves, so part size is not limited by a chamber.
Thickness
Set by your envelope and stopping distance, from thin solid skins to layered foam.
Simulation
We run your drops, strikes and vibration in FEA before anything is made.
Sample to production
A sample in 2 business days. The same machine runs your production order.
Parts we have made
Cast for real hardware, one part at a time.
Formulated and cast in our own USA facility for customer applications, from helmets to battery systems.
Quick look
The numbers engineers ask for first.
Ordering terms and the geometry we have made so far. If your part sits outside these, ask us. Most limits move with the formulation.
Ordering
- Minimum order
- One part
- Sample lead time
- 2 business days
- Production lead time
- Quoted per order
- CAD files
- STEP, STP or STL, up to 20 MB
- Where it is made
- Manufactured in the USA
Material and geometry
- Shape
- Any shape: solid, cored or lattice
- Part size
- No oven or autoclave limit
- Foam layer thickness
- 14 to 20 mm typical, 10 mm minimum
- Layered foam
- Up to about 30 mm, density-graded
- Solid polyurea skins
- Down to 0.66 mm
- Density
- About 100 to 355 kg/m³
- Tested additives
- Graphene, biocide, fire retardant
Thicker or larger parts are made by casting in layers or around a core. Tell us the envelope and we will tell you how we would build it.
Why this foam
Protective foam that takes hit after hit.
Our foam is a microcellular polyurea: light like foam, tough and resilient like an elastomer. Here is the tested baseline before we tune it to your part.
Energy absorbed per unit volume
Nearly 2x a leading commercial impact foam, 12% lighter (SDSU study, 2020)
Loss in load-bearing capacity
After 7 repeated impacts
Volumetric recovery
After a 25 m/s projectile impact
Lower peak head acceleration
Helmet liner vs closed-cell foam, 1 m drop (SDSU study estimate)
Baseline, not a limit. These are baseline values for our standard formulation, the kind of numbers a conventional material supplier would give you and stop at. They are a starting point, not a limit: we change the additive loading and cast the part to your geometry, so your part’s performance is tuned to your targets and will differ from these figures.
Full comparison and test conditionsVertically integrated
One company, start to finish.
Most protective foam reaches you through a chain: one company makes the chemistry, another pours sheets, a third cuts them. We do every step under one roof in the USA. That is why each part can have its own formula and shape and still be made in production.
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Formulate
We write a formula for your load case and environment.
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Cast
Cast to your shape on our own patent-pending automated machine.
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Simulate
FEA runs your drops, strikes and vibration before tooling.
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Sample
A physical sample in 2 business days to test on your hardware.
- 05
Produce
The same machine and formula run your production order.
Applications
Built for hardware that takes a hit.
Drone bodies, battery trays, sensor housings and more, shown in internal demonstrations.
Battery systemsEV passenger battery protection
Concept for a single cast battery tray that absorbs impact energy before it reaches the cells. Internal demonstration; crash performance is qualified for each vehicle program.
Drones and roboticsDrone body protection
A drone body cast in our elastomer in place of a multi-part assembly. In this demonstration it takes the impact, recovers its shape and keeps flying.
Battery systemsPortable battery unit protection
Impact protection for portable battery units that get dropped, thrown in vehicles and carried in the field.
Customer stories
Where our parts are in use right now.
Hardware teams using custom Super Foam parts today.
Customer · order placedBattery systems · extreme cold
Helicoid
Vibration-dampening case corners for battery boxes used in extreme cold.
- The challenge
- Battery boxes deployed in extreme cold take constant vibration and knocks, and cold makes many protective materials stiff and brittle just when they’re needed.
- What we’re doing
- Case corners cast from a formulation selected for extreme-cold use, dampening vibration around the battery box.
Active pilotAutonomous logistics
Glīd
Protecting sensors, compute and a soft-landing pad on the GliderM autonomous truck.
- The challenge
- Glīd’s GliderM truck carries sensitive sensors and a compute unit, and has to set a shipping container down without a jarring impact.
- What we’re doing
- Protective parts for the sensors and compute unit, plus a landing pad that cushions the soft loading of a shipping container onto the GliderM.
Active pilotMilitary & emergency power
New Use Energy
Protecting portable lithium-ion power banks built for military and emergency use.
- The challenge
- Portable power banks for the field get dropped, thrown in vehicles and carried into disaster zones, and they still have to work.
- What we’re doing
- Impact protection for the lithium-ion batteries and the compute units inside each power bank.
What is the minimum order?
One part. You can order a single sample or a single production part.
How fast can I get a sample?
Sample lead time is 2 business days. Production lead time is quoted per order.
What files do you accept?
STEP, STP or STL files up to 20 MB. No CAD yet? Describe the part, the envelope and what it has to survive, and we will start from that.
Can you really cast any shape?
The part is cast to your CAD: solid, cored or lattice, and molded around your hardware. The foam cures at room temperature with no ovens or autoclaves, so part size is not limited by a chamber. We flag thin walls or small features during the FEA review.
What can I change in the material?
Density (about 100 to 355 kg/m³), thickness, shape and size, plus tested additives: graphene for UV protection, stiffness and static dissipation, biocide to resist mold and bacteria, and fire retardant.
Where is it made?
In the USA. Formulation, casting on our own patent-pending machine, simulation and shipping all happen in-house. Every part is manufactured in the USA.
Is my design kept confidential?
Yes. Your files and requirements are only used to spec, simulate and make your part.
Tell us what the part has to survive.
Share the load case, the envelope and the environment. We reply with a material spec, a simulation plan and the next step to a sample.