What is Medical Grade Foam?


Medical grade foam is a product that meets the highest industry standards and is made from only raw materials that are approved by strict regulation. For healthcare industry machining, medical-grade polyurethane foam features higher quality and properties for use in clean or sterile environments.

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High-Quality Medical Foam Manufacturers

PFI’s medical-grade polyurethane foam will meet all of your needs in the healthcare industry. The following traits are essential in selecting a quality medical-grade foam to meet your specific application:

  • Flexibility and conformity
  • Mold and fungal resistance
  • Water absorption or resistance
  • Low outgassing
  • Impact absorption and compression-set resistance
  • Durability

Contact us to discuss your next manufacturing project.

(610) 856-7550

What Is Medical Grade Foam Manufacturing?

Medical foam manufacturing covers a broad range of materials, methods and products. Though the industry itself is not specifically defined and its product is open to subjective labeling, selecting a medical-grade foam fabricator should be based on the product meeting these standards:

  • ISO 10993 biocompatibility standards.
  • FDA approved. An approval could be met through a registered foam formulation on the FDA master file, utilizing FDA-registered raw materials, or a 510K premarket notification.
  • USP classification. Raw materials are registered for use in the pharmaceutical industry.

Medical device manufacturing is VOC free and not subject to off-gassing. Professional fabricators of medical foams such as PFI make a variety of products that vary in density, rigidity, shape, color, and thickness, pending your specific needs.

At PFI we’ve been fabricating for over 40 years and our medical-grade foam manufacturing is far above the industry standards as we produce the highest quality polyurethane medical foam.

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What Is Medical Grade Foam Made Of?

Foams can be made of a variety of substrates; polyethylene, polypropylene, polyvinyl chloride (PVC), polyurethane, and polystyrene to name a few. Polyurethane foam has become the staple in the healthcare technology industry. Polyurethane has several properties that give it a clear advantage for medical use. It is extremely biocompatible, high-strength, and flexible.

What Can Medical Grade Foam Be Used For?

There are countless uses for medical-grade foam. Depending on the application, medical foam can be manufactured to meet the specified requirements. The most common, polyurethane foams, can be fabricated with either open or closed cells. This variation is most relevant with water absorption or resistance. Common medical-grade foam applications are:

  • Medical cushioning/custom orthotics
  • Medical grade foam padding
  • Wound care
  • Liquid management and filtration
  • Medical grade mattress and pillows
  • Sterile medical packaging and shipping

At PFI, our expert fabricators can custom cut medical grade polyurethane to your custom applications.

What to Look For in a Medical-Grade Foam Manufacturer

When selecting a fabricator for your medical foam needs, a manufacturer with expertise and reputation is critical. PFI Advanced Equipment Manufacturing has an experienced team of foam machining experts. We also source our materials from North American suppliers.

At PFI we offer 40 years of custom foam fabrication, we offer you only the best with professional, experienced staff and cutting-edge technology. To get the finest medical-grade polyurethane foam, contact us today or call (610) 856-7550.

Jeff Rathfon

Jeff Rathfon is PFI’s Shop Operations Manager and blog writer. Jeff joined PFI at the end of January 2023 and is responsible for day-to-day operations of the business. Jeff has considerable experience as a shop supervisor and CNC machinist having spent years as a shop production supervisor at Isimac Manufacturing in Blandon PA and as a CNC Machinist/Team Leader at TD Connectivity in Jonestown, PA. Jeff is a skilled continuous improvement manager with both Lean Manufacturing and Six Sigma skills. Jeff is also a motor sports engineer.