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North America Foam Market Size, Share & Trends Analysis Report By Type (PU Foam, PS Foam, PVC Foam, Phenolic Foam, Polyolefin Foam), By Application (Packaging, Building & Construction), By Country, And Segment Forecasts, 2025 - 2033

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    Report

  • 120 Pages
  • July 2025
  • Region: North America
  • Grand View Research
  • ID: 6154588
Description Jump to:
The North America foam market size was estimated at USD 21.85 billion in 2024 and is projected to reach USD 35.04 billion by 2033, growing at a CAGR of 5.1% from 2025 to 2033. The market is projected to grow steadily, fueled by increasing demand from important industries like packaging, construction, automotive, and furniture.

The growth of e-commerce is greatly enhancing the need for protective and cushioning foams, while tougher insulation regulations and the transition toward lighter automotive materials are also promoting foam usage throughout the region.

The North America foam industry is projected to experience consistent growth, fueled by robust demand in the packaging, automotive, construction, and healthcare industries. Foam materials are essential for improving thermal insulation in buildings, lowering vehicle weight for enhanced fuel efficiency, and providing protective cushioning for packaging and medical uses. The increasing focus on energy-efficient infrastructure, the rise of electric vehicles, and the growth of e-commerce are major factors driving demand in the region. Furthermore, the transition towards recyclable, low-VOC, and bio-based foam products is accelerating, driven by regulatory requirements and corporate sustainability objectives in both the U.S. and Canada.

In North America, increasing urbanization, continuous improvements in infrastructure, and the swift growth of cold chain logistics are leading to a higher demand for foam across various sectors. As producers focus on performance, longevity, and compliance with environmental regulations, the need for advanced foam materials in insulation, protective packaging, and temperature-sensitive transportation is projected to rise consistently in the future.

North America Foam Market Report Segmentation

This report forecasts revenue growth at the regional and country levels and provides an analysis of the latest industry trends in each of the sub-segments from 2021 to 2033. For this study, the analyst has segmented the North America foam market report based on type, application, and country:
  • Type Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)
  • Polyurethane Foam
  • Polystyrene Foam
  • PVC Foam
  • Phenolic Foam
  • Polyolefin Foam
  • Polyethylene Foam
  • Polypropylene Foam
  • Melamine Foam
  • Other Foam Types
  • Application Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)
  • Packaging
  • Food & Beverage packaging
  • Industrial protective packaging
  • Consumer Electronics Packaging
  • E-Commerce Mailers & Shipping
  • Pharmaceuticals & healthcare packaging
  • Building & Construction
  • Insulation boards (walls, roofs, floors)
  • Soundproofing/acoustic panels
  • HVAC duct insulation
  • Sealants & gap fillers
  • Waterproofing membranes
  • Furniture & Bedding
  • Mattresses
  • Upholstered furniture cushions
  • Office chairs
  • Foam toppers & pads
  • Automotive
  • Seating foam
  • Interior trim & headliners
  • Acoustic insulation
  • Bumper & crash pads
  • Air filters & HVAC foams
  • Other Applications
  • Country Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)
  • North America
  • U.S.
  • Canada
  • Mexico

Why should you buy this report?

  • Comprehensive Market Analysis: Gain detailed insights into the global market across major regions and segments.
  • Competitive Landscape: Explore the market presence of key players worldwide.
  • Future Trends: Discover the pivotal trends and drivers shaping the future of the global market.
  • Actionable Recommendations: Utilize insights to uncover new revenue streams and guide strategic business decisions.

This report addresses:

  • Market intelligence to enable effective decision-making
  • Market estimates and forecasts from 2018 to 2030
  • Growth opportunities and trend analyses
  • Segment and regional revenue forecasts for market assessment
  • Competition strategy and market share analysis
  • Product innovation listing for you to stay ahead of the curve
  • COVID-19's impact and how to sustain in these fast-evolving markets

This product will be delivered within 1-3 business days.

Table of Contents

Chapter 1 Methodology and Scope
1.1 Market Segmentation & Scope
1.2 Market Definitions
1.3 Information procurement
1.3.1 Information analysis
1.3.2 Market formulation & data visualization
1.3.3 Data validation & publishing
1.4 Research Scope and Assumptions
1.4.1 List of Data Sources
Chapter 2 Executive Summary
2.1 Market Snapshot 2024
2.2 Segment Snapshot (1/2)
2.3 Segment Snapshot (2/2)
2.4 Competitive Landscape Snapshot
Chapter 3 North America Foam Market: Variables and Trends
3.1 Market Lineage Outlook
3.1.1 North America Plastic Market Outlook
3.2 Industry Value Chain Analysis
3.2.1 Raw Material Trends
3.2.1 Technology Trends
3.2.1 Sales Channel Analysis
3.3 Supply Chain Integration
3.3.1 Raw Material Supply Chains for Polymer Foam
3.4 Regulatory Framework
3.4.1 Policies and Incentive Plans
3.4.2 Standards & Compliances
3.5 Market Dynamics
3.5.1 Market Driver Analysis
3.5.1.1 Expansion in Automotive Manufacturing & Adoption of EV
3.5.1.2 Robust Growth of E-commerce Sector
3.5.2 Market Restraint Analysis
3.5.2.1 Environmental Concerns and Plastic Waste Regulations
3.5.3 Industry Challenges
3.5.4 Industry Opportunities
3.6 Market Business Environment Analysis
3.6.1 Industry Analysis: Porter’s Five Forces Model
3.6.2 Macroeconomic Environment Analysis
Chapter 4 North America Foam Market: Type Estimates & Trend Analysis
4.1 Type Movement Analysis & Market Share Volume, 2024 & 2033
4.2 Type Movement Analysis & Market Share Revenue, 2024 & 2033
4.3 North America Foam Market Estimates & Forecasts, by Type (Kilotons) (USD Million)
4.3.1 Polyurethane Foam
4.3.1.1 Polyurethane North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.2 Polystyrene Foam
4.3.2.1 Polystyrene North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.3 PVC Foam
4.3.3.1 PVC North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.4 Phenolic Foam
4.3.4.1 Phenolic North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.5 Polyolefin Foam
4.3.5.1 Polyolefin North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.5.2 Polyethylene (PE) Foam
4.3.5.2.1 Polyethylene (PE) North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.5.3 Polypropylene (PP) Foam
4.3.5.3.1 Polypropylene (PP) North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.6 Melamine Foam
4.3.6.1 Melamine North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
4.3.7 Other foam types
4.3.7.1 Other foam types Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Chapter 5 North America Foam Market: Application Estimates & Trend Analysis
5.1 Application Movement Analysis & Market Share Volume, 2024 & 2033
5.2 Application Movement Analysis & Market Share Revenue, 2024 & 2033
5.3 North America Foam Market Estimates & Forecasts, by Application (Kilotons) (USD Million)
5.3.1 Packaging
5.3.1.1 Foam in Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.1.2 Food & Beverage packaging
5.3.1.2.1 Foam in Food & Beverage packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.1.3 Industrial protective packaging
5.3.1.3.1 Foam in Industrial Protective Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.1.4 Consumer electronics packaging
5.3.1.4.1 Foam in Consumer Electronics Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.1.5 E-commerce mailers & shipping
5.3.1.5.1 Foam in E-commerce mailers & shipping Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.1.6 Pharmaceuticals & healthcare packaging
5.3.1.6.1 Foam in Pharmaceuticals & Healthcare Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.2 Building & Construction
5.3.2.1 Foam in Building & Construction Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.2.2 Insulation boards
5.3.2.2.1 Foam in Insulation boards Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.2.3 Soundproofing/acoustic panels
5.3.2.3.1 Foam in Soundproofing/Acoustic Panels Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.2.4 HVAC duct insulation
5.3.2.4.1 Foam in HVAC duct insulation Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.2.5 Sealants & gap fillers
5.3.2.5.1 Foam in Sealants & Gap Fillers Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.2.6 Waterproofing membranes
5.3.2.6.1 Foam in Waterproofing Membranes Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.3 Furniture & Bedding
5.3.3.1 Foam in Furniture & Bedding Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.3.2 Mattresses
5.3.3.2.1 Foam in Mattresses Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.3.3 Upholstered furniture cushions
5.3.3.3.1 Foam in Upholstered Furniture Cushions Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.3.4 Office chairs
5.3.3.4.1 Foam in Office Chairs Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.3.5 Foam toppers & pads
5.3.3.5.1 Foam in Foam Toppers & Pads Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.4 Automotive
5.3.4.1 Foam in Automotive Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.4.2 Seating foam
5.3.4.2.1 Foam in Seating North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.4.3 Interior trim & headliners
5.3.4.3.1 Foam in Interior Trim & Headliners Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.4.4 Acoustic insulation
5.3.4.4.1 Foam in Acoustic Insulation Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.4.5 Bumper & crash pads
5.3.4.5.1 Foam in Bumper & Crash Pads Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.4.6 Air filters & HVAC foams
5.3.4.6.1 Foam in Air Filters & HVAC Foams Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
5.3.5 Other applications
5.3.5.1 Foam in Other Applications Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Chapter 6 North America Foam Market: Country Estimates & Trend Analysis
6.1 North America Foam Market: Country Outlook
6.2 North America
6.2.1 North America Foam Market estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
6.2.2 U.S. Foam Market estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
6.2.3 Canada Foam Market estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
6.2.4 Mexico Foam Market estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Chapter 7 North America Foam Market: Competitive Landscape
7.1 Recent Developments & Their Impact Analysis, by Key Market Participants
7.2 Company Categorization
7.3 Company Market Positioning Analysis, 2024
7.4 Strategy Mapping
7.4.1 Expansions
7.4.2 Mergers & Acquisitions
7.4.3 Product Launches
7.4.4 Partnerships/Collaborations
7.5 Company Heat Map Analysis
Chapter 8 North America Foam Market: Company Profiles
8.1 Participant’s Overview
8.2 Financial Performance
8.3 Product Benchmarking
List of Tables
Table 1 List of Abbreviations
Table 2 Type market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 3 PU North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 4 PS North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 5 PVC North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 6 Phenolic North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 7 Polyolefin North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
a. PP North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
b. PE North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 8 Melamine North America Foam Market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 9 Other Foam Types market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 10 Application market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 11 Packaging market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 12 Building & Construction market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 13 Automotive market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 14 Furniture & Bedding market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 15 Other Applications market estimates and forecasts, 2021 - 2033 (USD Million) (Kilotons)
Table 16 North America North America Foam Market estimates and forecasts, by Type, 2021 - 2033 (USD Million) (Kilotons)
Table 17 North America North America Foam Market estimates and forecasts, by application, 2021 - 2033 (USD Million) (Kilotons)
Table 18 US North America Foam Market estimates and forecasts, by Type, 2021 - 2033 (USD Million) (Kilotons)
Table 19 US North America Foam Market estimates and forecasts, by application, 2021 - 2033 (USD Million) (Kilotons)
Table 20 Canada North America Foam Market estimates and forecasts, by Type, 2021 - 2033 (USD Million) (Kilotons)
Table 21 Canada North America Foam Market estimates and forecasts, by application, 2021 - 2033 (USD Million) (Kilotons)
Table 22 Mexico North America Foam Market estimates and forecasts, by Type, 2021 - 2033 (USD Million) (Kilotons)
Table 23 Mexico North America Foam Market estimates and forecasts, by application, 2021 - 2033 (USD Million) (Kilotons)
List of Figures
Fig. 1 North America Foam Market Segmentation
Fig. 2 Information procurement
Fig. 3 Data analysis models
Fig. 4 Market formulation and validation
Fig. 5 Data validating & publishing
Fig. 6 Market snapshot, 2024
Fig. 7 Segment snapshot, 2024 (1/2)
Fig. 8 Segment snapshot, 2024 (2/2)
Fig. 9 Competitive Landscape Snapshot, 2024
Fig. 10 North America Foam Market-Industry Value Chain Analysis
Fig. 11 North America Foam Market Dynamics
Fig. 12 Total Annual Production of Vehicles, 2021 - 2024 (Units)
Fig. 13 Global EV Production, 2021 to 2033 (Units)
Fig. 14 North America Foam Market: PORTER’s Analysis
Fig. 15 North America Foam Market: PESTEL Analysis
Fig. 16 North America Foam Market, by Type: Key Takeaways
Fig. 17 North America Foam Market, by Type: Market Share Volume, 2024 & 2033
Fig. 18 North America Foam Market, by Type: Market Share Revenue, 2024 & 2033
Fig. 19 Polyurethane North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 20 Polystyrene North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 21 PVC North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 22 Phenolic Foam Polyurethanes Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 23 Polyolefin North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 24 Polyethylene (PE) North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 25 Polypropylene (PP) North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 26 Melamine North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 27 Other foam types Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 28 North America Foam Market, by Application: Key Takeaways
Fig. 29 North America Foam Market, by Application: Market Share Volume, 2024 & 2033
Fig. 30 North America Foam Market, by Application: Market Share Revenue, 2024 & 2033
Fig. 31 Foam in Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 32 Foam in Food & Beverage Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 33 Foam in Industrial Protective Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 34 Foam in Consumer Electronics Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 35 Foam in E-commerce Mailers & Shipping Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 36 Foam in Pharmaceuticals & Healthcare Packaging Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 37 Foam in Building & Construction Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 38 Foam in Insulation boards Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 39 Foam in Soundproofing/Acoustic Panels Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 40 Foam in HVAC duct insulation Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 41 Foam in Sealants & gap fillers Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 42 Foam in Waterproofing membranes Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 43 Foam in Furniture & Bedding Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 44 Foam in Mattresses Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 45 Foam in Upholstered furniture cushions Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 46 Foam in Office chairs Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 47 Foam in Foam toppers & pads Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 48 Foam in Automotive Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 49 Foam in Seating North America Foam Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 50 Foam in Interior trim & headliners Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 51 Foam in Acoustic insulation Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 52 Foam in Bumper & crash pads Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 53 Foam in Air filters & HVAC foams Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 54 Foam in Other Applications Market Estimates & Forecasts, 2021 - 2033 (Kilotons) (USD Million)
Fig. 55 North America Foam Market revenue, by Country, 2024 & 2033 (USD Million)
Fig. 56 Country marketplace: Key takeaways
Fig. 57 U.S. Foam Market estimates & forecast, 2021 - 2033 (Kilotons) (USD Million)
Fig. 58 Canada Foam Market estimates & forecast, 2021 - 2033 (Kilotons) (USD Million)
Fig. 59 Mexico North America Foam Market estimates & forecast, 2021 - 2033 (Kilotons) (USD Million)
Fig. 60 Company Market Positioning Analysis, 2024 (1/2)
Fig. 61 Company Market Positioning Analysis, 2024 (2/2)

Companies Mentioned

  • Arkema Group
  • Armacell International S.A.
  • BASF SE
  • Borealis AG
  • SABIC
  • Japan Polypropylene Corporation
  • Braskem
  • Exxon Mobil Corporation
  • LyondellBasell Industries Holdings B.V.
  • Huntsman Corporation
  • Evonik Industries AG
  • Covestro AG
  • Fritz Nauer AG (acquired by Recticel NV)
  • Koepp Schaum GmbH
  • JSP Corporation
  • Polymer Technologies, Inc.
  • Recticel NV
  • Rogers Corporation
  • SEKISUI ALVEO AG
  • Synthos S.A.
  • DuPont de Nemours, Inc.
  • Trelleborg AB
  • Zotefoams plc
  • Woodbridge Foam Corporation
  • Sealed Air Corporation

Table Information

Report AttributeDetails
No. of Pages120
PublishedJuly 2025
Forecast Period2024 - 2033
Estimated Market Value ( USD ) in 2024 $ 21.85 Billion
Forecasted Market Value ( USD ) by 2033 $ 35.04 Billion
Compound Annual Growth Rate5.1%
Regions CoveredNorth America
No. of Companies Mentioned25

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About the Plastic Foam Market

Plastic foam is a type of plastic material that is lightweight, flexible, and durable. It is often used in a variety of applications, such as insulation, packaging, and cushioning. Plastic foam is made from a variety of polymers, including polystyrene, polyurethane, and polyethylene. It is available in a range of densities, colors, and sizes, and can be customized to meet specific needs. Plastic foam is widely used in the construction industry, as it is an effective insulator and can be used to reduce energy costs. It is also used in the automotive industry, as it is lightweight and can be used to reduce the weight of vehicles. In addition, plastic foam is used in the packaging industry, as it provides cushioning and protection for products. The plastic foam market is highly competitive, with a number of companies offering a range of products. Some of the major players in the market include BASF, Dow Chemical, Huntsman Corporation, and Armacell. These companies offer a variety of products, including insulation, cushioning, and packaging materials. Show Less Read more

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