Foam Design Inc.

Foam Design Inc., a woman-owned small business manufacturer based in Lexington, Kentucky, supplies specialized foam fabrication, cushioning materials, packaging solutions, and ammunition containers to the Department of Defense as a prime contractor on 190 awards (83% of recent activity) and as a subcontractor on 38 awards (17%), competing predominantly under total small business set-asides on its prime delivery orders and BPA calls.

The vendor's capability portfolio centers on urethane and polyethylene foam products, custom cushioning, anti-static foam components, shipping and storage containers, wooden crates and pallets, adhesives, and ammunition packaging for naval ordnance, munitions, and precision-guided weapon systems. Representative prime work includes a $277,125 delivery order from Naval Sea Systems Command (NAVSEA) awarded January 15, 2026, for production of MK 152 foam cushions under a total small business set-aside with CMMC requirements; a $1.41 million single-award indefinite delivery contract with NAVSEA for MK 152 foam cushions (awarded November 7, 2024, running through November 6, 2029) under total small business set-aside; a $1.05 million definitive contract from Army Joint Munitions Command (awarded August 31, 2022) for approximately 12,630 wood boxes to specification MIL-DTL-2427J; and a $130,649 BPA call from Joint Munitions Command for Advanced Precision Kill Weapon System (APKWS) packaging materials.

Customer concentration is extreme and Navy-anchored. The top five funding agencies account for 66% of awards by count, but NAVSEA dominates by potential value — 63 awards carry $4.05 billion combined potential value, representing 99% of the vendor's total portfolio. The ranking by potential value and by award count diverge sharply: NAVSEA anchors nearly all dollars through large IDVs and BPAs, while Army Joint Munitions Command (31 awards, $4.3 million) and Defense Logistics Agency Troop Support (46 combined awards, $6.9 million) provide volume through smaller transactional awards. This concentration exposes the vendor to NAVSEA program interruption or recompete risk.

Foam Design holds multiple large indefinite delivery vehicles. The vendor sits on NAVSEA's $4 billion Seaport Next Generation (Seaport-NXG) multiple-award contract (awarded January 2, 2025, running through January 1, 2029) with a minimum guarantee task order of $500 issued March 6, 2025. It also holds a $9 million single-award Blanket Purchase Agreement with Naval Air Warfare Center (awarded December 12, 2024, running through December 15, 2029), a $1.41 million single-award indefinite delivery contract with NAVSEA for MK 152 foam cushions (awarded November 7, 2024), a $7.5 million multiple-award BPA with Army Combat Capabilities Development Command Armaments Center for packing and crating (awarded June 24, 2024, running through June 25, 2029), and a $50 million single-award BPA with NAVSEA for fabrication and machine shop services (awarded October 1, 2022, running through September 30, 2027). Task orders flow across these vehicles: 20 task orders under the $50 million NAVSEA fabrication BPA carry $353 thousand combined value; 10 task orders under an indefinite delivery vehicle carry $795 thousand; 8 task orders under a Joint Munitions Command indefinite delivery contract are tracked without dollar value in the source. Smaller BPAs with Joint Munitions Command and other Army entities round out the vehicle portfolio.

Activity has held flat at 12–18 awards per year over the past five years (2022–2025) with only three awards recorded in 2026 year to date. The recompete cliff is minimal: only one award (the Joint Munitions Command polyethylene tube BPA call valued at $22,200.64, with ultimate completion February 16, 2026) faces completion inside the next twenty-four months. This low recompete exposure reflects the vendor's substantial holdings of multi-year IDVs and BPAs.

Foam Design operates as a subcontractor to major defense primes supplying foam fabrication and cushioning components. General Dynamics Ordnance & Tactical Systems is the most frequent prime partner, with sub awards for cushion components, foam packaging, and miscellaneous components supporting 25-millimeter, 30-millimeter, and 120-millimeter ammunition programs (awards spanning June 2022 through February 2026). Northrop Grumman Systems Corporation receives foam and urethane products from Foam Design for 120-millimeter tank training ammunition, 30-millimeter cartridges, and precision guidance kit production (awards from May 2024 through February 2026). Lockheed Martin, Bell Boeing Joint Project Office, Alliant Techsystems Operations, and ManTech Mgs receive smaller sub awards for foam insulation, pad foam, and ammunition components. The sub work is narrow in scope — foam and cushioning for ordnance and aerospace programs — and routes the vendor's capability into defense contractors' supply chains rather than direct DoD prime relationships.

NAICS concentration is tight: 73 of 228 awards fall under Urethane and Other Foam Product Manufacturing, and 29 awards fall under Ammunition Manufacturing. PSC concentration shows packaging and packing materials (59 awards), ammunition boxes and containers (28 awards), and specialized shipping containers (14 awards) as the dominant buy categories. The vendor's footprint is structurally dependent on NAVSEA's Seaport-NXG vehicle and its associated cushion and fabrication work; the collapse of that single customer would eliminate 99% of the portfolio's potential value despite 83% of awards being primes.

MIl Spec FOAM PRODUCTS,Polyethylene foams, Polyurethane foam, polypropylene foam,foam DUNNAGE FOR SHIPPING AND STORAGE CONTAINERS. Design of foam products. Packaging Design. Container Design.Certified under MIL-I-45208A.