Welcome to Polyformes, the UK’s largest foam converter and supplier.
For over 40 years, we’ve been at the forefront of the foam manufacturing and conversion industry. Operating from our custom-built 55,000 sq ft production facility in Leighton Buzzard, Bedfordshire, we are proud to be recognised as one of Europe’s leading converters of high-performance closed-cell polyethylene foam.
From initial concept to precision design, manufacturing, and final delivery, we provide custom foam engineering and solutions from a single, convenient source. And rather than off-the-shelf compromises, we instead produce custom solutions with a tailored level of performance, protection, and that add tangible value to your operations.
By working with Polyformes, you can expect several benefits and advantages:
Established in 1977, Polyformes began with a clear mission: to bring specialist knowledge, expertise and innovation to closed-cell polyethylene foam conversion. Originally operating out of a modest 2,000 sq. ft. factory, our dedication to quality, continuous research and development (R&D), and investment has resulted in strong, lasting growth.
Today, our 60-strong workforce operates from our main manufacturing unit, a 30,000 sq ft facility within an extensive 55,000 sq ft site. We combine state-of-the-art automated technology with our accumulated manufacturing knowledge to deliver unmatched quality and material expertise to businesses across the UK and Europe.
In July 2024, Polyformes became part of the Macfarlane Group, the UK’s largest protective packaging distributor. This further strengthens Polyformes position as experts within the foam packaging industry, as well as providing a huge range of additional products for our customers.
Our core expertise lies in the design, engineering and conversion of closed-cell polyethylene foams such as Plastazote, Ethafoam and Stratocell (among many others).
As a result, we specialise in custom foam packaging, bespoke inserts, engineered technical components, and an almost limitless range of custom foam products for industries including aerospace, defence, medical, automotive, electronics, retail and many more.
We have also forged close relationships with global leaders in foam materials, including Sealed Air Corporation, and O.K. Company, enabling us to stock, supply, and convert an extensive range of technical foams. We are also proud to be one of the first Zotefoams-approved fabricators in the UK.
Our modern, well-invested manufacturing facility enables us to undertake a wide range of foam conversion processes, including CNC routing, die cutting, waterjet cutting, thermoforming, splitting, skiving, laser engraving, and even printing.
See these processes in action by watching our behind-the-scenes video.
Alongside our expertise in foam, we can also offer you a huge range of outer cases and packaging products.
Polyformes is proud to be the official UK stockist and distributor of Explorer Cases. Virtually indestructible, completely waterproof, and shockproof, these NATO-stock-numbered protective cases provide protection for high-value equipment, weaponry, and sensitive electronics. We can also supply a wide range of other branded protective cases to suit any specific application.
In addition, we manufacture custom flight cases in-house. Our dedicated design and production teams work closely with you to produce flight cases that are the optimal size, strength and appearance for your requirements.
And regardless of which case you select, we can of course customise them with bespoke foam inserts.
Polyformes places great importance on the quality of the products we manufacture and on how we run our business.
We are proud to be accredited to ISO 9001:2015 for our quality management systems. This certification ensures that our design, manufacturing, and foam conversion processes consistently meet both customer and regulatory requirements.
Polyformes is also committed to striving towards several quality objectives. These include no non-conforming parts reaching our clients, delivering on time and in full, 100% of the time, and continuously striving to deliver the highest levels of client satisfaction.
Registered Legal Entity:
Company Registration Number:
Registered Office:
Head Office Location:
Contact Phone:
Contact Email:
Disclaimer: Generative Ai may be used on this site when specifically creating content and information relating to the products, processes and materials we use at Polyformes. Any Ai content undergoes stringent reviews and editing by humans to check accuracy. Please view this content policy for further details.
Send us a message
If you need high-performance foam inserts, packaging, products or materials, we can help. Please contact a member of our team for a free consultation and quote.
This form will collect your personal information to answer your enquiry. For information on the data we collect and how we use your information, please see our privacy policy.
Our experts
The information on this page was written and checked by our team of experts. You can contact them to discuss your requirements, or for any questions you may have, using the details here.
Sales Enquiries
[email protected]
01525 852 444 (option 1)
Accounts Enquiries
[email protected]
01525 852 444 (option 2)
