Our
Manufacturing
Capabilities
Full-service foam conversion and manufacturing for B2B customers — precision cutting through to complete OEM mattress production.
Our core capability is precision foam conversion — transforming raw foam blocks and sheets into precisely dimensioned components that meet exact customer specifications. Using CNC-controlled cutting technology, we achieve consistent tolerances across high-volume production runs.
We cut across all standard foam grades including polyurethane, memory foam, latex and specialist acoustic or fire-retardant materials. Components can be produced in virtually any two-dimensional profile, with bespoke thickness specifications and complex multi-step profiles.
No two manufacturing requirements are alike. AJ Foam works with procurement teams and product developers to specify foam components that precisely meet their application requirements — whether that's a specific density rating, compression force deflection value, or a complex multi-layer composite component.
We offer profiling services including convoluted foam, channelled profiles for ventilation, stepped layers and bonded composite constructions combining multiple foam grades in a single component.
AJ Foam manufactures complete mattresses through our in-house brands — Pureflex, Neptune and Rêve — as well as for OEM customers. Our mattress manufacturing capability spans foam-only, all-foam layered and hybrid construction formats.
Production is managed from component conversion through to finished product, including fabric covering, handle and border tape application and packaging. We work to retail-ready quality standards and can accommodate branded or unbranded finishing.
We provide fully confidential OEM and white-label manufacturing for retailers, brands and manufacturers requiring their own-brand foam products. All OEM arrangements are supported by non-disclosure agreements and we never reveal the details of our manufacturing relationships.
Whether you need a single product manufactured to your specification or a full product range produced under your brand, our OEM service provides the precision and discretion your business requires.
All foam materials supplied and manufactured by AJ Foam meet UK fire safety regulations, including the requirements of The Furniture and Furnishings (Fire Safety) Regulations. We maintain full material traceability across our supply chain and hold documentation to support compliance audits.
Our quality control process includes incoming material inspection, dimensional verification during production and outgoing inspection prior to despatch. We work to documented quality procedures and can support customer-specific quality requirements on request.
Through the Oneiro division, AJ Foam is actively developing and introducing sustainable foam materials as alternatives to conventional petroleum-based polyurethane foams. This includes bio-based foam grades, recycled content materials and initiatives to reduce manufacturing waste.
We work with customers who have sustainability commitments to identify appropriate responsible material specifications that meet both their performance and environmental requirements.
Discuss Your Technical Requirements
Our technical team will work with you to find the right foam specification for your application.