Custom Foam Core Products & Kitting

KPI Concepts produces precision-cut foam core components, routed foam parts, and organized foam kits built to customer drawings, mold requirements, and production needs.

Foam Core Products

What We Make

From simple foam blocks to routed, contoured, and kit-ready components, KPI supports custom foam core projects with precision cutting and repeatable production.

Foam Core Kits

Matched foam components prepared for customer assembly, mold placement, or composite layup.

Routed Foam Panels

Foam panels with pockets, slots, grooves, holes, and other routed details.

Hot Wire Cut Profiles

Profile-cut foam shapes for curved forms, contours, and repeatable geometry.

Contoured Foam Components

Shaped foam parts produced to match customer drawings, molds, and fit requirements.

Sheets, Blocks & Blanks

Foam sheets, blocks, and blanks prepared for downstream fabrication or customer use.

Custom Cut Foam Parts

Specialty foam components cut, shaped, and organized around project-specific needs.

Foam Core Kitting

Organized Foam Kits Built Around Your Project

Foam core kits can include matched parts, numbered components, routed details, curved sections, and stacked or nested pieces prepared for efficient customer assembly or layup.

KPI helps reduce in-house cutting time by preparing foam components to match the geometry, sequence, and production requirements of each project.

Numbered foam kit parts
Matched and grouped components
Nested or stacked kit layouts
Built to drawings and requirements
Custom Foam Core Kitting Components Arranged As Numbered Kit Parts
Cutting & Shape Options

Cut, Routed & Shaped Foam Core Components

Choose from flat, routed, grooved, contoured, curved, slotted, drilled, and profile-cut foam components based on your application requirements.

Hot Wire Foam Cutting Process For Foam Core Materials

Hot Wire Cut Foam

Efficient profile cutting for repeatable contours, curves, and foam core shapes.

Cnc Foam Cutting For Routed Foam Core Components

CNC Routed Foam

Routed pockets, holes, grooves, slots, and detailed geometry for custom foam parts.

Custom Shaped Foam Core Component After Cutting

Finished Foam Core Parts

Custom shaped foam components produced to support fit, layup, and production requirements.

Start a Foam Core Project

Send Us Your Drawings or Requirements

KPI Concepts can help produce custom foam core components, routed foam parts, and kitted foam assemblies built around your project specifications.

White Foam Core Material For Custom Foam Core Products