Foam Design is a company that has been providing foam solutions and exceeding customer expectations for 44 years. They offer various manufacturing capabilities such as water jet cutting, milling, and molding to create custom foam parts and inserts. Their materials include reticulated foams, urethane, melamine, and military-grade Ethafoam. They specialize in providing defense, aerospace, and industrial customers with foam solutions for critical applications.

1. ChrisHarrodcharrod@foamdesign.com(502)682-8562
NAICS Codes:
326150: Urethane and other foam products
326199: All other plastics product
manufacturing.
488991: Packing and crating
541420: Industrial design Services
DUNS: 07-132-4479
ITAR Registered Code M35304
Cage Code: 1T579
EIN: 61-0865119
IS0-9001:2015 & AS9100D
Registration #C2015-00023
Federal Government System
for Award Management (SAM)
44 YEARS OF MILITARY CUSHIONING EXCELLENCE
Foam Design offers solutions for all facets of today’s ever
changing commercial and industrial landscape. From
start-ups to established industries, we work relentlessly to
exceed your requirements. Founded in 1974, Foam
Design has been converting foam and surpassing our
client’s expectations for over 44 years.
Our conversion capabilities and design expertise provide
defense and aerospace customers with foam solutions for
mission critical devices that require intricate parts cut to
precise tolerances.
Our experienced and knowledgeable engineers can
create custom foam interiors to fit any plastic or metal
containers – from the most basic container models to the
latest design.
DEFENSE AND MUNITIONS
AVIATION PRODUCTS
ENGINEERED SOLUTIONS
AVIATION SAFETY PRODUCTS
MANUFACTURING
CAPABILITIES
• Five-Axis Water Jet Cutting
• Five-Axis Milling
• Horizontal Wire Profile Cutting
• Vertical Wire Profile Cutting
• Die Cutting
• Post Molding
• Cross-Linked PE Foam
• Convoluting
• RIM Urethane Molding
• Reticulated PU Fabrication
• Slitting and Skiving
• Foam Tube Forming
• Lamination – Heat/Adhesive
• Case Services & Capabilities
• Custom Manufacturing
• Design Custom Inserts
FEATURED & STOCK
MATERIALS
• Reticulate Foams
• Rigid Urethane Molding
• Melamine Foam
• HDPE
• UHMW
• 100% Compostable Packing
• Acoustical Foam
• Water Filtration Foam
• Petroleum Absorbing Foams
• Rubber and Neoprene
• Ethafoam
• Military Grade Ethafoam
• Zote Foams
• Crosslink (XLPE)
• Plastic Corrugated
• Expanded Polypropylene
• Expanded Polyethylene
• EVA cross-linked foams
• Polyurethane
• Specialty Foam
• Composites
• Felts
• OPAN
• Polyimide

2. Materials Density Material Size Color Special Properties Military Specification
Polyethylene Plank 2 PCF 2" x 48" x 108" Black LEL< 10 CID A-A 59136 Type I, Grade A
Polyethylene Plank 4 PCF 2" x 48" x 108" Black LEL< 10 CID A-A 59136 Type III, Grade A
Polyethylene Plank 6 PCF 2" x 48" x 108" Black LEL< 10 CID A-A 59136 Type IV, Grade A
Polyethylene Plank 9 PCF 2" x 48" x 108" Black LEL< 10 CID A-A 59136 Type V, Grade A
Polyethylene Plank 2 PCF 2" x 48" x 108" White LEL< 10 CID A-A 59136 Type I, Grade A
Polyethylene Plank 4 PCF 2" x 48" x 108" White LEL< 10 CID A-A 59136 Type III, Grade A
Polyethylene Plank 6 PCF 2" x 48" x 108" White LEL< 10 CID A-A 59136 Type IV, Grade A
Polyethylene Plank 9 PCF 2" x 48" x 108" White LEL< 10 CID A-A 59136 Type V, Grade A
Polyethylene Plank 2 PCF 2" x 48" x 108" Pink LEL< 10, Anti-Static CID A-A 59136 Type I, Grade B
Polyethylene Plank 4 PCF 2" x 48" x 108" Pink LEL< 10, Anti-Static CID A-A 59136 Type III, Grade B
Polyethylene Plank 2 PCF 2" x 48" x 108" Light Brown LEL< 10, FR CID A-A- 59136, Class 1, Grade C, Type I.
Polyethylene Plank 2 PCF 2" x 48" x 108" Blue Grey LEL< 10, FR, Anti-Static CID A-A- 59136, Class 1, Grade D, Type I.
• Density-Pounds per Cubic Foot (PCF)
• 10% LEL (Lower Explosion Limit) of residual blowing agents required for enclosed military applications. Certification is provided with each shipment of
Ethafoam® M-Series products.
Foam planks shall be of the following types, classes, and grades as specified.
Class 1 - General purpose polyethylene plank material (unskived).
Class 2- General purpose polypropylene plank material (unskived).
Class 3 - General purpose plank material, polymer specified by the Procuring Activity (unskived).
Class 4- Special purpose (skived) sheets, planks, and shapes as specified by the Procuring Activity.
Grade A - Standard.
Grade B - Static dissipative.
Grade C - Fire retardant
Grade D - Static dissipative and Fire retardant
Type I - 14 Kg Constant Compression Creep
Type III - 21 Kg Constant Compression Creep
Type IV - 25 Kg Constant Compression Creep
Type V - 37 Kg Constant Compression Creep
Density- The nominal density of the material when tested:
Type I - 32 Kg/M3 (2 PCF) Nominal Density Cushioning Material.
Type III - 64 Kg/M3 (4 PCF) Nominal Density Cushioning Material.
Type IV - 96 Kg/M3 (6 PCF) Nominal Density Cushioning Material.
Type V - 144 Kg/M3 (9 PCF) Nominal Density Cushioning Material.
Grade A - The color shall be black or white.
(Black is most common for Grade “A”)
Grade B - The color shall be pink.
Grade C - The color shall be light brown.
Grade D - The color shall be blue-grey.
Note: A-A-59136 – Paragraph 3.8 “Color For
Reference only, unless otherwise specified.
Chris M. Harrod
Sales Development Engineer
(859)-231-7006 ex. 2223
(502)-682-8562 Cell
444 Transport Court
Lexington, KY 40511
foamdesign.com
militaryfoam.com
linkedin.com/in/chris-m-harrod
Foam Design A-A-59136 “Class 1” Polyethylene Plank Materials