Real-world solutions to complex challenges

Case Studies

Explore how our foam solutions have solved complex challenges across various industries, delivering significant improvements in performance, efficiency, and cost-effectiveness.

Success Stories

Explore how our foam solutions have solved complex challenges across various industries

Automotive

NVH Solution for Premium Vehicle

NVH Solution
Challenge:

A luxury automotive manufacturer needed to reduce cabin noise in their premium sedan while minimizing weight and maintaining cost targets.

Solution:

We developed a custom XLPE foam solution with targeted density variations to address specific frequency ranges, combined with a proprietary lamination process for optimal performance.

Results:
  • 40% reduction in cabin noise
  • 15% weight reduction compared to previous solution
  • Met all cost targets
  • Improved customer satisfaction ratings
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Electronics

Protective Packaging for Sensitive Components

Protective Packaging
Challenge:

An electronics manufacturer needed a protective packaging solution for shipping sensitive components that would provide superior protection while reducing costs and environmental impact.

Solution:

We developed a custom PET foam solution with variable density zones, optimized for maximum protection with minimal material usage, and designed for efficient manufacturing.

Results:
  • 85% reduction in shipping damage
  • 30% material reduction
  • 25% cost savings
  • 100% recyclable solution
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Medical

Patient Comfort Solution for Medical Device

Patient Comfort
Challenge:

A medical device manufacturer needed a foam solution for patient contact that would provide superior comfort, meet biocompatibility requirements, and withstand repeated cleaning.

Solution:

We developed a custom urethane foam formulation with a specialized surface treatment that met all biocompatibility requirements while providing exceptional comfort and durability.

Results:
  • Passed all biocompatibility testing
  • 40% improvement in patient comfort ratings
  • 3x increase in durability
  • Resistant to hospital-grade disinfectants
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Industrial

HVAC Thermal Insulation Solution

Thermal Insulation
Challenge:

An HVAC manufacturer needed a thermal insulation solution that would provide superior energy efficiency, meet fire safety requirements, and reduce installation time.

Solution:

We developed a custom XLPE foam solution with enhanced thermal properties, integrated fire retardants, and a pre-applied adhesive system for rapid installation.

Results:
  • 25% improvement in thermal efficiency
  • Met all fire safety requirements
  • 50% reduction in installation time
  • 15% overall cost reduction
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Automotive

Lightweight Seating Solution

Lightweight Seating
Challenge:

An automotive manufacturer needed to reduce the weight of their seating system while maintaining comfort, durability, and safety performance.

Solution:

We developed a hybrid foam system combining different densities of urethane foam with strategic reinforcement zones to optimize weight, comfort, and durability.

Results:
  • 22% weight reduction
  • Improved comfort ratings
  • Passed all safety and durability tests
  • 10% cost reduction
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Construction

Weather-Resistant Expansion Joint Solution

Expansion Joint
Challenge:

A construction company needed an expansion joint material that would withstand extreme weather conditions, provide excellent compression recovery, and offer long-term durability.

Solution:

We developed a custom EPDM foam formulation with enhanced UV and ozone resistance, optimized compression set properties, and a specialized surface treatment for improved adhesion.

Results:
  • 3x improvement in weather resistance
  • 95% compression recovery after long-term compression
  • Estimated 15+ year service life
  • 30% reduction in installation time
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Client Testimonials

What our clients say about our solutions

"Plastomer's engineering team went above and beyond to solve our complex NVH challenge. Their custom foam solution not only met our performance requirements but also helped us reduce weight and cost. Their expertise and collaborative approach made all the difference."

John D.

Engineering Manager, Automotive Manufacturer

"We had struggled with packaging damage issues for years until we partnered with Plastomer. Their innovative foam solution reduced our damage rates by over 80% while actually reducing our packaging costs. Their technical expertise and attention to detail were impressive."

Sarah M.

Supply Chain Director, Electronics Manufacturer

"Plastomer's custom foam formulation for our medical device was a game-changer. Patient comfort scores improved dramatically, and the material has proven extremely durable even with rigorous cleaning protocols. Their understanding of our unique requirements was exceptional."

Michael R.

Product Development Director, Medical Device Company

Ready to Solve Your Foam Application Challenge?

Our engineering team is ready to develop a custom solution for your specific requirements.