Flexible Foam Market Report 2026

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%. 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.

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