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CNC machine used in custom foam molding at RCO Engineering

 

Our Custom Foam Services

Custom foam services include:

  • Automotive & aerospace seating
  • Low volume production programs
  • One-off prototypes
  • Large scale foam projects
  • Foam assemblies with various densities


RCO can design and fabricate the perfect custom molded foam solution in various densities, colors, and textures.

 

Molded Foam Prototypes

RCO uses advanced equipment for custom milled and molded foam work. Our experienced team can create custom foam molded products like cushions and backs for premium seating. We can also produce other foam-based components for the automotive, defense, and VIP aerospace industries.

RCO has the capacity for:

 

We’re proud to be trusted by top global brands as leading experts in foam seating.

Example of aerospace foam product made through custom foam molding at RCO Engineering

Molded Foam Benefits

Molded foam offers many benefits over other types of foam:

  • more durable and has a longer lifespan
  • more resistant to water, chemicals, and temperature extremes
  • provide superior support and comfort when properly designed

 

Custom Molded Foam Services

RCO provides complete custom molded foam services, including design, prototyping, production, and assembly. Our team has extensive experience in Molded foam technology and can assist you with every step in molded foam manufacturing.

We can design custom foam molded seats to fit your specific vehicle. Our team can deliver any:

  • shape
  • size
  • density
  • color
  • texture

 

Similarly, we design foam prototypes to your specifications for testing fit, form, and function. Our prototypes in a variety of materials, including foam, plastic, and metal.

 

Man uses machine for custom foam molding at RCO Engineering

In Our Molded Foam Facility You’ll Find

 

We create custom foam molding prototypes using:

  • CNC FOAM MILLS
  • POLYURETHANE FOAM MOLDING POUR MACHINES
  • SKIVED FOAM STATIONS
  • MEASUREMENT, TESTING, AND DEVELOPMENT IN OUR IN-HOUSE ILD LAB
  • EXPERTISE WITH FOAM MEETING PART 25

Large saw used for custom foam molding at RCO Engineering

 

Molded Foam Commodities

We can create a range of custom foam molded products including:

  • SEAT BACKS
  • SEAT CUSHION
  • BOLSTERS
  • HEAD RESTS
  • FOOT RESTS
  • ARM RESTS
  • FOAM CONSOLES

Trusted Foam Manufacturing Partner for Tier 1 Suppliers & OEMs

RCO Engineering is a full-service contract manufacturer specializing in molded and milled foam for the automotive, aerospace, and defense industries. As a trusted Tier 1 supplier partner, we work directly with OEMs and their supply chains to deliver production-ready foam components — from initial concept through volume production.

Whether you need a single prototype cushion or a low-volume production run of molded polyurethane foam seating, RCO provides the engineering expertise, in-house tooling, and manufacturing capacity to keep your program on schedule.

Why we're different:
- Dedicated engineering support from quote to delivery
- In-house foam tooling design and fabrication — no outsourcing delays
- AS9100D certified facility with full traceability
- Flexible capacity for high-mix, low-volume programs
- Single-source accountability: design, prototype, tool, produce, and assemble under one roof

Enterprise Foam Solutions — From Prototype to Production

RCO delivers end-to-end foam fabrication services built for enterprise-scale programs. Our foam capabilities go beyond basic molding — we engineer complete foam systems including multi-density assemblies, bonded foam sub-assemblies, and integrated foam-and-trim packages ready for installation.

Our foam fabrication capabilities include:

- Molded Polyurethane Foam — Custom-poured foam in open and closed molds for seat cushions, backs, bolsters, armrests, and headrests
- CNC Milled Foam — Precision-machined foam components from billets, ideal for prototyping and low-volume programs
- Foam Tooling — In-house design and fabrication of foam molds and fixtures, reducing lead times and costs
- Multi-Density Foam Assemblies — Engineered comfort zones using multiple foam formulations within a single component
- Skived Foam — Precision-cut foam layers for applications requiring exact thickness control

We work with a wide range of polyurethane foam formulations to meet your specific performance requirements — including fire-retardant foams compliant with FAR Part 25 for aerospace applications.

Low Volume Foam Production & High-Mix Manufacturing

Not every foam program requires 100,000 pieces. RCO specializes in low volume foam production and high-mix, low-volume manufacturing — the sweet spot where large-scale foam producers often can't (or won't) compete.

We're built for programs that need:

- Prototype quantities (1–10 pieces) with production-intent quality
- Low volume production runs (10–5,000 pieces per year)
- Multiple SKUs and configurations managed under one roof
- Engineering changes incorporated mid-program without costly retooling
- Short lead times — weeks, not months

Our foam production team manages complex programs with dozens of unique part numbers simultaneously. If your program has been turned away by high-volume foam suppliers, or if you're tired of being deprioritized on their production schedule, RCO is the partner you need.

Foam for Aerospace, Fleet, and Specialty Vehicle Interiors

RCO Engineering is a proven foam supplier for VIP aerospace interiors, fleet vehicle seating, and specialty vehicle applications. Our AS9100D-certified facility and experienced engineering team make us a trusted partner for programs where quality, traceability, and regulatory compliance are non-negotiable.

Aerospace foam capabilities:
- Molded foam cushions and backs for VIP and executive aircraft seating
- FAR Part 25 compliant foam formulations (flammability, smoke, and toxicity)
- Complete seat assemblies including foam, trim, and metal frames
- Certification documentation and full material traceability

Fleet and specialty vehicle foam:
- Transit bus and rail seating foam
- Emergency vehicle seating components
- Military and defense vehicle seat cushions and pads
- Custom foam solutions for specialty vehicle OEMs

Get a Foam Quote in 24–48 Hours

Ready to start your foam project? RCO's engineering team reviews every quote request personally — no automated pricing, no generic estimates. Send us your drawings, CAD files, or even a napkin sketch, and we'll respond with a detailed quote including:

- Material recommendations based on your performance requirements
- Tooling costs and options (if applicable)
- Piece price at your target volumes
- Estimated lead time from order to delivery

We quote foam projects of all sizes — from a single prototype to ongoing production programs. No project is too small, and no requirement is too complex.

Certifications & Quality

RCO Engineering operates from a 150,000+ sq. ft. facility in Roseville, Michigan, with certifications and standards including:

- AS9100D — Aerospace quality management system
- IATF 16949 compliant processes for automotive programs
- In-house ILD testing lab for foam hardness and performance verification
- Full program management — APQP, PPAP, and FAIR documentation as required
Man adjusting foam during custom foam molding process at RCO Engineering
Man finishing foam product after custom foam molding at RCO Engineering
Man hardworking molded foam after custom foam molding at RCO Engineering

Contact Us About Our Custom Foam Molded Products Today

RCO Engineering is proud to offer our Molded Foam products to better serve you. Contact us for more information—our team is ready to answer your questions and discuss your project.