Foam Fabrication

HS Foam Fabricators utilize a wide array of fabrication techniques, ranging from the simplest straight cut to the most intricate die-cut shapes, including highly accurate CNC cutting.
 

With state-of-the-art cutting equipment and our extensive knowledge of assembly, we work one on one with our customers to create custom fabricated parts for their upholstered furniture and consumer product needs.

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HS Foam Fabricators offer customers turnkey solutions for high-quality, precise fabrication on a wide selection of materials. 

Foams We Use

​​Conventional Foams — an extensive range of standard foams from super-soft to very firm, light to heavy densities.

California 117-2013 Foams — formulated without fire retardants to meet California's Technical Bulletin 117-2013, required of furnishings intended for sale in California.

Code*Red II® Foam — fire-retardant, high-performance foam suited for use where British, Boston, and/or Cal. 133 specifications are required.

 

High Resilience (HR) Foams — valued for their high support factor, high resilience foams are most often utilized in top-quality seating and premium bedding.

Reticulated Foam — extremely high porosity (airflow) makes HSM’s reticulated foams ideal for outdoor furniture cushions, filter media, and other specialty uses.

Anti-Stat Foams — specially formulated foam which dissipates electrostatic charges for packaging sensitive electronic equipment.

 

Rebond Foam — high-density reconstituted foam manufactured for various markets including school bus seating, golf cart seating, furniture parts, and carpet underlay offered in a variety of grades.

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What We Do

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CNC FABRICATION
(Foam & Fiber Batting)

 

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CUT & SEW
DIE-CUTTING

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BLOWN FIBER-FILL
DOWN FEATHER CUSHIONS

 

CONVOLUTING
CONTOUR CUTTING

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Our Markets

Grey Sofa
Clean Boat
Surgeons
Hotel Lounge
Industrial Building
Bright Conference Room

Our Capabilities

At Hickory Springs Foam Fabricators we specialize in fabricating polyurethane and polyethylene foams with the following processes. 

 

Furniture Fabrication ​

  • Blown fiberfill

  • Convoluting cut

  • Contour cut

  • CNC fabrication (foam and fiber batting)

  • Cut & sew

  • Die-cut

  • Down & feather cushions

  • Molded foam

Foam Fabrication ​Processes

  • CNC Contour Cutting

    • Horizontal & Vertical

  • Contour Cutting

  • Vertical Slitting

  • Die Cutting

  • Adhesive Lamination

  • Molded foam

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Cushion Products

Blown-Fiber Backs

Blown fiber is ideal for back cushions and pillows, offering various levels of back support and adapt to multiple cushion styles. We stock a number of different fibers and casings.

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Down and Feather Cushions

Every seat cushion we make can be customized to provide the desired look and feel. Cushion options include those made with down and feathers only, foam-down cushions and spring-down cushions.

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Foams

We supply any foam required to build furniture, from simple arm and back foam to high-density, high-resilience foams for outstanding performance. Our foam cushions are the most environmentally friendly foams on the market, CertiPUR-US®-certified while meeting/exceeding California’s stringent Prop 65 requirements. We can also provide foams that meet strict fire codes for special orders.

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Reticulated Foam

For drainable outdoor cushions, we carry several grades of reticulated foam that can be encased in a special mesh or made with a sewn, drainable cover.

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Spring Cushions

For long-lasting comfort, we provide a variety of innerspring cushions that produce the exact amount of firmness and seat-depth desired. These springs can be encased in a wide range of foam grades and wrapped in thermal-bonded fibers or encased in a jacket containing blown fiber.

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Where We Are Located

With multiple locations over the US, HS Foam Fabricators are able to provide on-time delivery to customers with the same quality everywhere.

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OPERATION LOCATIONS

 

FLORIDA
Hickory Springs Foam Fab (Ocala)

 

IOWA
Hickory Springs Foam Fab (Monticello)

 

INDIANA
Hickory Springs Foam Fab (New Castle)

 

KENTUCKY
Hickory Springs Foam Fab (Owensboro)

 

MISSISSIPPI
Hickory Springs Foam Fab (Verona)

 

NORTH CAROLINA
HSM Corporate Office (Hickory)
Hickory Springs Foam Fab (Hickory)
Hickory Springs Foam Fab (Hiddenite)
Hickory Springs Foam Fab (High Point)
Hickory Springs Foam Fab (Lenoir)

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TELL US ABOUT YOUR PROJECT

Looking for a custom foam solution? We’re here to help. Send us a message or give us a call, and we’ll help you find the right product for your project.