Our lightweight, closed-cell automotive foams deliver precise, durable gap-filling solutions that improve panel alignment and reduce NVH across automotive body structures.
Our Automotive foam materials
From lightweight interior components to high-performance insulation in engine bays and structural reinforcement as composite core materials, our automotive foams deliver superior durability, efficiency, and performance.
- Lightweight; lower densities outperform
- Cold-resistant; prevents structural and engine damage from freezing
- Moderate to high heat-resistant; improves safety and performance
- Impact-resistant; component and passenger protection
- Outstanding compression strength and low compression set; maintains seals and reduces NVH
- Excellent thermal insulation; regulates automotive components
- Chemical- and solvent-resistant; prevents degradation and ensure long-term performance
- Among the lowest emissions & fogging values’; exceeding regulatory standards
Why is foam used in Automotive applications?
Lightweighting
Foam is lightweight but strong, helping to reduce the overall weight of the vehicle.
Lower weight improves fuel efficiency and helps meet emissions targets.
Noise, Vibration, and Harshness (NVH) Reduction
Foam reduces sound and dampens vibrations, making the ride quieter, and more comfortable.
Impact Protection and Safety
Energy-absorbing foams are used in bumpers, side panels, knee bolsters and headrests to protect passengers in case of a collision.
Aesthetic and Structural Use
Foams are moulded into specific shapes for car interior design elements. They also can be combined with fabrics or leather for premium finishes.
Comfort and Ergonomics
Foams are used in car seats, armrests, door panels and steering wheels to provide cushioning and long-term comfort.
Thermal Insulation
Foams help regulate vehicle interior temperature by insulating against heat and cold. Used in HVAC ducts and around the engine bay to prevent heat transfer.
Sealing and Water Resistance
Closed-cell foams provide sealing against moisture, dust, and air leaks. Helps improve the efficiency of air conditioning and prevents vehicle rust from moisture build up.
Purity and Emissions Standards
Foams are used for their low VOC emissions, fogging resistance, and odour control, ensuring better in-cabin air quality and compliance with global purity standards.
Where are our materials often used?
Common applications of our automotive foam within a car
Seal against water, air, sound and chemicals
Composite front-end structures for impact protection
Engine covers/Heat shield
Bonnet (hood) liners
Dashboard spacer
Roof liner spacer
Comfort underlayer
Dust seal
Battery insulation wrap
AC/ventilation ducting
Mirror housing seal
Automotive Applications
Bodypanel Gap Filler
Automotive Applications
Bulkhead/Firewall Grommet
Our foams provide reliable, compression-resistant sealing for bulkhead and firewall grommets, ensuring effective isolation of noise, heat, and vibration.
Automotive Applications
Door Seal
Our resilient closed-cell automotive foams create long-lasting, lightweight door seals that enhance comfort, weather protection, and overall vehicle refinement.
Automotive Applications
Ducting
Our thermally efficient foams enable robust ducting solutions that improve airflow performance and durability throughout the vehicle.
Automotive Applications
Protective Cover
Our heat-resistant, lightweight foams are used as durable protective covers that safeguard vehicle components while improving thermal management.
Automotive Applications
Shock Absorber Cover
Our lightweight foams deliver durable shock absorber covers that protect components from debris while reducing noise and vibration.
Automotive Applications
Speaker Gasket
Our precision-engineered foams create reliable speaker gaskets that enhance acoustic performance while providing long-term sealing and vibration control.
Automotive Applications
Under Bonnet Gap Filler
Our closed-cell automotive foams provide lightweight, durable under-bonnet gap fillers that improve sealing, reduce NVH, and enhance overall engine-bay refinement.
Automotive Applications
Window Seal
Our foams deliver long-lasting door window and windscreen seals that enhance weather protection, reduce noise, and improve overall cabin comfort.
Automotive Applications
Mirror Housing Seal
Lightweight, conformable foams provide reliable mirror flag housing seals that minimise wind noise, prevent water ingress, and enhance exterior durability.
EV Battery Applications
Our superior automotive foam materials offer a unique combination of insulation, compression performance and flame retardance that make them a clear winner in high purity and lightweight materials for various battery pack applications.
From cushioning and cell spacing to fire protection and lightweighting, we deliver engineered foam solutions designed for the next generation of electric mobility.
Zotefoams materials for Automotive Applications
Application Engineering Support
Our experienced Application Engineering team works closely with customers to optimise material selection, design, and processing. From concept to commercialisation, we provide tailored technical support to help you get the best performance from Zotefoams materials in your application.
What makes Zotefoams unique?
Three-Stage Manufacturing
Our unique nitrogen expansion manufacturing process delivers pure, uniform and durable materials.
Sustainability
Our technology and efficient use of raw materials allows us to develop lighter more durable products.