The polyurethane foam market has seen considerable growth due to a variety of factors.
•The market share for polyurethane foam has experienced robust expansion in the last few years. It's projected to escalate from $54.27 billion in 2024 to $58.04 billion in 2025, with a compound annual growth rate (CAGR) of 6.9%.
The surge during the historic period is due to the flourishing construction sector, usage in automotive interiors, furniture production, refrigeration and appliances, along with the rising demand in the footwear industry.
The polyurethane foam market is expected to maintain its strong growth trajectory in upcoming years.
• In the coming years, the polyurethane foam market is projected to experience robust growth, set to reach a market size of $81.2 billion in 2029, growing at a compound annual growth rate (CAGR) of 8.8%.
This anticipated growth during the forecast period can be linked to factors such as the rise of renewable and bio-based polyurethane foams, an increasing requirement for lightweight materials, a heightened focus on thermal insulation, an expansion in healthcare applications, and growing packaging needs within the e-commerce sector. During the forecast period, several significant trends are expected to emerge, including innovation in composite materials, the implementation of circular economy practices, the advent of smart insulation solutions, the development of sustainable packaging innovations, and the introduction of advanced comfort technologies in the bedding market.
The polyurethane foam market is poised to grow, propelled by the increasing demand for automotive vehicles. Automotive vehicles, which are self-propelled and used for public transportation, often utilize polyurethane foam for their car seats and upholstery due to its superior cushioning, comfort, and durability, creating a pleasant and supportive seating experience for drivers and passengers alike. As per data provided by Japan's MarkLines Co., Ltd, an internet-based information provider for the auto industry, light vehicle sales in the U.S. rose by 13.0% in December 2023, amounting to 1,454,597 units sold. This boosted demand was especially noted in trucks and SUVs, which experienced a 15.7% increase compared to December 2022. Overall, the year saw a 12.3% increase in automotive sales, resulting in 15,608,386 units sold, indicating a strong resurgence of consumer interest in various vehicle categories. Consequently, the augmenting demand for automotive vehicles is fueling the expansion of the polyurethane foam market.
The polyurethane foam market covered in this report is segmented –
1) By Type: Rigid Foam, Flexible Foam, Spray Foam
2) By Process: Slabstock Foam, Molded Foam, Lamination, Spraying
3) By Density Composition: Low-Density Composition, Medium-Density Composition, High-Density Composition
4) By Application: Bedding And Furniture, Transportation, Packaging, Automotive, Construction, Electronics, Footwear, Other Applications
Subsegments:
1) By Rigid Foam: Polyisocyanurate Foam, Polyurethane Foam, Structural Insulated Panels (SIPs)
2) By Flexible Foam: Polyether Flexible Foam, Polyester Flexible Foam, High Resilience (HR) Foam
3) By Spray Foam: Open-Cell Spray Foam, Closed-Cell Spray Foam, High-Density Spray Foam
Leading companies in the polyurethane market are concentrating on developments in technology, particularly lightweight, long-lasting polyurethane foam technologies created to support and secure cells in electric vehicle (EV) batteries. As an example, in April 2024, Huntsman Corporation, a US company that manufactures and markets chemical products for both consumer and industrial use, launched a new series of lightweight, hard-wearing SHOKLESS polyurethane foam technologies. These were specifically developed for the support and securement of cells within electric vehicle (EV) batteries, offering better thermal and structural safeguarding. Such innovative developments are intended to solve industry problems by presenting flexible manufacturing alternatives and strong performance, catering to the escalating demand for superior solutions in the automotive industry.
Major companies operating in the polyurethane foam market include:
• BASF SE
• Dow Inc.
• Saint-Gobain S.A.
• Wanhua Chemical Group Co Ltd
• Covestro AG
• DuPont de Nemours Inc.
• Sekisui Chemical Co. Ltd.
• Huntsman Corporation
• Lanxess AG
• Nitto Denko Corporation
• Carpenter Co.
• FXI Holdings Inc.
• Woodbridge Foam Corporation
• JSP Corporation
• Rogers Corporation
• Armacell International S.A.
• Future Foam Inc.
• Reciticel N.V.
• UFP Technologies Inc.
• FoamPartner Group
• Greiner Perfoam GmbH
• Zotefoams PLC
• Foamcraft Inc.
• Eurofoam GmbH
• Synthesia Internacional SL
• American Excelsior Company
• General Plastics Manufacturing Co.
• Innocor Inc.
Asia-Pacific was the largest region in the polyurethane foam market in 2024. It is expected to be the fastest-growing region in the forecast period. The regions covered in the polyurethane foam market report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East, Africa.