Kewell Converters Ltd
About us
Kewell Converters are independent UK foam converters specialising in high-performance foam solutions for defence, aerospace, industrial and product protection applications. We engineer reliable, repeatable foam components where performance matters.
Our approach is solutions-led. We partner with customers to specify and engineer foam that delivers protection, reliability and long-term durability as a functional part of the system, not a commodity.
Operating from our UK factory, we provide advanced CNC foam conversion, CAD/CAM design support, prototyping and repeatable production. This enables us to support projects from early concept through to long-term supply.
We deliver a wide range of applications including aircraft interior panels, gaskets and seals, acoustic insulation, electrostatic materials, fire-performance foams, impact and shock protection, case inserts and long-life reusable transit solutions.
As an approved Zotefoams distributor, we specify and convert materials including Plastazote®, Evazote®, Supazote®, Ecozote® and Zotek® for demanding and safety-critical environments.
Independent, agile and engineering-led, Kewell Converters are trusted by customers who need foam components to perform consistently every time.
Products & services
Case insert converting
Precision-crafted protection for your valuable assets Explore our specialised range of Foam Case Inserts, a premium offering in Kewell Converters’ expansive product range. Uniquely engineered to provide tailored protection, our Plastazote foam case inserts aren’t merely functional. These multi-functional foam packing materials also enhance the visual appeal of your packaged goods. With the integration of state-of-the-art technology and personalisation, you can depend on us to deliver unparalleled solutions for safeguarding your products during transit.
Volume manufacturing
Expert fabrication of precision 2D foam components At Kewell Converters, our extensive technological arsenal and advanced machining capabilities empower us to craft a diverse range of 2D foam components tailored to serve a plethora of industries. As a leading foam converter, we meticulously transform foam materials into high-precision 2D products, leveraging a blend of state-of-the-art machinery and our team’s vast expertise.
Waterjet Cutting
Precision-engineered foam gaskets: The Kewell Distinction In the realm of advanced engineering, Kewell Converters stands at the forefront of producing top-tier foam gaskets. Our offerings cater to a myriad of industries where the demand for reliability and adherence to strict performance criteria is of the utmost importance.
Bespoke Foam Solutions
Engineered foam components designed around your application Every project starts with understanding how the foam needs to perform in the real world. Kewell Converters specialises in bespoke foam solutions developed to meet specific functional, environmental and regulatory requirements. We work closely with customers at the design stage to select the right materials, define tolerances and optimise part geometry. This approach ensures consistent performance, repeatability and long service life, whether the foam is providing protection, insulation, sealing or structural support. Our in-house capabilities allow us to prototype, test and refine components before moving into production, reducing risk and accelerating development timelines. From one-off engineered parts to repeat production runs, bespoke foam solutions are tailored to the demands of defence, aerospace, industrial and product protection applications. Visit our stand to see examples of custom-engineered foam components and discuss how bespoke design can improve performance in your system.
Turnkey Foam Solutions
A complete, end-to-end approach to foam project delivery What sets Kewell Converters apart isn’t just what we make, it’s how we deliver. Our turnkey approach means we manage more of the supply chain so you don’t have to. We take responsibility for material sourcing, coordination with third-party suppliers and oversight of the full production workflow. This reduces supplier complexity, shortens lead times and provides one reliable point of contact from concept through to delivery. Whether producing bespoke military foam inserts for defence case systems, aerospace-grade foam panels or complex assemblies for industrial automation, every project is handled with the same focus on quality, compliance and delivery confidence. Turnkey foam solutions are ideal for customers who value clarity, accountability and engineering-led project management. Visit our stand to learn how an integrated approach can simplify your next programme.
Gaskets & Seals
Precision-cut sealing solutions for demanding environments Kewell Converters manufactures high-performance foam gaskets and seals designed to deliver reliable sealing across a wide range of industrial, aerospace and defence applications. We work with a broad range of technical foam materials to achieve the required levels of compression, resilience, chemical resistance and environmental durability. Tight tolerances and consistent material behaviour are central to every design. Our gaskets and seals are used to manage vibration, prevent ingress, maintain pressure integrity and support long-term system reliability. From simple flat gaskets to complex multi-layer assemblies, each component is engineered for repeatable performance in service. See examples of precision-cut gaskets and sealing solutions on our stand and talk to our team about material selection and design optimisation.
Buoyancy & Floatation
Engineered foam solutions for marine and safety-critical use Buoyancy and flotation applications demand materials that perform consistently over time, even in harsh environments. Kewell Converters supplies engineered foam solutions designed to deliver reliable flotation, low water absorption and long-term durability. We work with closed-cell foams suited to marine, offshore and safety equipment applications where predictable buoyant performance is critical. Components can be supplied as precision-cut parts, bonded assemblies or fully integrated solutions. Applications include flotation aids, marine equipment, protective systems and specialist industrial uses where weight, stability and environmental resistance matter. Visit our stand to explore buoyancy foam materials and discuss how engineered flotation solutions can be tailored to your application.
High Temperature Foam Applications
Foams designed to perform under heat and pressure High-temperature environments place unique demands on foam materials. Kewell Converters supplies and converts specialist foams capable of maintaining performance when exposed to elevated temperatures, thermal cycling and demanding operating conditions. These materials are commonly used for thermal protection, fire performance, insulation and sealing in aerospace, defence and industrial systems. Material selection focuses on stability, resistance to degradation and predictable behaviour over time. Our engineering-led approach ensures components are designed with the full operating environment in mind, not just laboratory specifications. Visit our stand to see examples of high-temperature foam components and discuss suitable materials for heat-critical applications.
Thermal & Acoustic Insulation
Managing heat, sound and vibration through engineered foam Thermal and acoustic performance is increasingly critical in modern engineered systems. Kewell Converters provides foam solutions that help control heat transfer, reduce noise and manage vibration across a wide range of applications. We support customers with material selection and component design to achieve specific thermal conductivity, sound absorption or damping characteristics. Solutions are used in aerospace interiors, industrial equipment, enclosures and transport applications where comfort, efficiency and compliance matter. By treating foam as a functional engineering material rather than a commodity, we help customers achieve consistent, repeatable performance in demanding environments. Explore our thermal and acoustic insulation solutions on the stand and speak with our team about your performance requirements.