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North America Flexible Foam Market - By Type (Polyurethane, Polyethylene, Polypropylene, Silicone, Ethylene-Vinyl Acetate (EVA), Melamine, Polyvinylidene Fluoride (PVDF)) and End-Use & Forecast, 2022-2028

  • Report ID: GMI5234
  • Published Date: Mar 2022
  • Report Format: PDF

North America Flexible Foam Market Size

North America Flexible Foam Market size was valued at USD 7.60 billion in 2021 and is estimated to exhibit a CAGR of 5.8% from 2022 to 2028 owing to the rapidly growing furniture industry. In terms of volume, the market is projected to record 3.9% CAGR while reaching 3,670.6 Kilo Tons.

north america flexible foam market outlook

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Flexible foam finds extensive uses across various end use industries. In furniture & upholstery, the product is rapidly replacing traditional materials such as rubberized coir and cotton. Also, furniture & upholstery along with the automotive industry has become profitable avenues for industry participants as flexible foam emerged as the cushioning material of choice among both manufacturers & consumers.

Technological advancements that enable the development of flexible foams that are lightweight, durable, and better-insulated will fuel the product adoption in the sector. The product has the ability to integrate aesthetics with functionality in several types of furniture and upholstery such as home & office furniture, chairs, pillows, designer sofas, public seating in stadiums, cinema houses, airports, etc., steering the demand in the industry. In addition, the shifting preferences toward foam mattresses over spring mattresses among consumers will drive the North America flexible foam market share.

Infrastructure development and residential and commercial sector expansion are driving the North America flexible foam market forward. Furthermore, continued technological developments and the expansion of flexible foam manufacturers into the United States, Canada, and Mexico will have a favorable impact on the construction sector. The demand for furniture is likely to increase as residential development activities increase. Flexible foam is widely utilized in the furniture business as a cushioning material for upholstered furniture.

North America Flexible Foam Market Analysis

north america flexible foam market by type

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Polyurethane flexible foam dominates the overall market and will account for more than 60% revenue share by 2028. Polyurethane is the major type of flexible foam used across end-use industries. The diverse applicability of the product has gained substantial demand from sectors such as automotive, packaging, furniture, and construction. Favorable properties such as resiliency, light weightiness, sound absorption, chemical stability, and flexibility make it an ideal material across these applications. In addition, the growing demand for foams with reduced wastage and elevated recyclability will bolster the North America flexible foam market sales in the near future.

Polyethylene foam has considerable utilization in the packaging industry and will generate a revenue of around USD 1.3 billion by 2028. They are primarily used as protective packaging for sensitive products such as electronic equipment, automotive parts, and luxurious furniture. The product is easy to process and fabricate. It also possesses significantly high load-bearing capacity when compared with other foams, making it the preferred packaging foam across various sectors.

north america flexible foam market by end use

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Based on end-use, the North America flexible foam market from furniture & upholstery will generate a demand of around 1.5 million tons by 2028. In furniture & upholstery, the product is used owing to its cushioning property. Mattresses, pillows, chairs, sofa sets, and carpet underlay are the major products that utilize flexible foam in the furniture & upholstery industry. The low-density, low heat conduction coefficient, resistance to moisture, and lightweight nature of the product, when compared to traditional materials such as cotton and rubberized coir, have augmented its usage in the sector.

Flexible foam has revolutionized the automotive industry owing to its contribution in enhancing safety, durability, weight, and comfort in vehicles. The product is mainly used in seating, vibration dampening, sound, and thermal insulation applications. Superior stress and tensile properties along with resistance to solvents have further bolstered the product utilization in the sector.

north america flexible foam market by country

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U.S. emerges as the largest & most influential market and will witness around 5.5% CAGR over the forecast timeframe. The presence of a diverse market consisting of end-users and end-use industries will offer a lucrative market for industry participants. The relaxation of investment norms by major economies has resulted in several automotive, furniture, consumer goods, and packaging industries establishing their manufacturing operations in the region. Additionally, the prospering trade activities and supportive trade regulations will augment the North America flexible foam market revenue over the forecast timeline.

North America Flexible Foam Market Share

The North America flexible foam market displays high degree fragmentation with the presence of large multinational players & several regional players. Leading companies operating in the North America flexible foam industry are

  • BASF
  • Covestro
  • DOW Chemical
  • Huntsman
  • Rogers Corp
  • The Woodbridge
  • INOAC Corp
  • Carpenter
  • Kaneka
  • American Excelsior Company

The North America flexible foam market report includes in-depth coverage of the industry with estimates & forecast in terms of revenue (USD Million) and volume (Kilo Tons) from 2022 to 2028 for the following segments:

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By Product

  • Polyurethane
    • Polyester
    • Polyether
  • Polyethylene
    • Cross linked
    • Non-cross linked
  • Polypropylene
  • Silicone
  • Ethylene-vinyl acetate (EVA)
  • Melamine
  • Polyvinylidene fluoride (PVDF)

By End-use

  • Furniture & upholstery
  • Packaging
  • Construction
  • Consumer goods
    • Clothing & footwear
    • Household & personal care
    • Others
  • Transportation
    • Automotive
    • Railway
    • Aerospace

The above information is provided on a country basis for the following:

By Region

  • U.S.
  • Canada
  • Mexico


Authors: Kiran Pulidindi, Akshay Prakash

Frequently Asked Questions (FAQ) :

The flexible foam industry is slated to surpass USD 11 billion by 2028 and is poised to record a CAGR of 5.8% between 2022 and 2028 due to the fast-growing furniture sector in the region.

The polyurethane flexible foam is expected to account for over 60% of the regional market share by 2028 driven by rising application scope in the automotive, packaging, furniture, and construction sectors.

The flexible foam industry size in North America from the furniture & upholstery end-use segment is likely to cross 1.5 million tons, in volume, by 2028 owing to the increasing need for mattresses, pillows, chairs, sofa sets, and carpet underlay.

The flexible foam market in the U.S. is poised to strike a 5.5% CAGR through 2028 on account of the robust presence of diverse end-use industries in the country.

North America Flexible Foam Market Scope

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Premium Report Details

  • Base Year: 2021
  • Companies covered: 11
  • Tables & Figures: 109
  • Countries covered: 3
  • Pages: 150
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