AF One MFG Inc. – Custom Foam Packaging Solutions

PROUDLY MADE IN CANADA

Your Trusted Foam Manufacturing Partner for Products & Packaging

AF One MFG Inc. are experienced leaders in foam manufacturing, delivering quick, reliable, and affordable custom solutions for your product manufacturing and packaging needs.

Partner with us for precision, quality, and consistency, ensuring your projects are completed on time with every cut.

ISO 9001 Certified • CertiPUR US • Intertek

Home of Quality Canadian Brands for Over 30 Years

We don’t just manufacture foam products and packaging — we build brands that bring comfort, support, and everyday function into homes across Canada. From orthopedic comfort to kids furniture and innovative sleep products, discover the consumer brands built by AF One MFG.

FOR CAREGIVERS

Orthopedic Comfort & Support

BodyForm Orthopedic offers expertly crafted foam products designed to support comfort, recovery, and everyday wellness. From orthopedic sleep solutions to specialized support cushions, our products are built to deliver reliable pressure relief, lasting comfort, and practical support for home, healthcare, and daily living.

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FOR KIDS

Excite Your Child's Imagination

ComfyKids creates soft, durable foam furniture designed for play, relaxation, and everyday family life. From flip chairs and sofas to loungers and modular foam blocks, the product line combines comfort, imagination, and Canadian-made quality to fit naturally into playrooms, bedrooms, and shared living spaces.

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FOR EVERYONE

The Mattress That Keeps Its Shape

The Flipper Foam Mattress is designed for sleepers who want dependable support and comfort that lasts. Its flippable foam design helps prevent sagging, dipping, and body valleys over time, delivering a sleep surface that holds its shape, feels consistent, and feels brand new every time you change your sheets.

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CAPABILITIES

Industry Leading Equipment For Endless Foam Possibilities

We own and operate a comprehensive range of state-of-the-art equipment, designed to meet the unique demands of your project. Our cutting-edge machinery ensures precision, efficiency, and quality across various manufacturing processes, allowing us to deliver tailored solutions that exceed your expectations.

Convoluted Foam

Convoluted foam features a textured surface designed to cushion and protect delicate items during shipping or storage. Its unique peaks and valleys absorb shocks and vibrations, making it ideal for packaging fragile electronics, medical devices, or consumer goods.

CNC Cut Foam

CNC-cut foam uses computer-controlled machinery for precision shaping. In packaging, it ensures exact fits for complex components like automotive or aerospace parts, while in products, it creates intricate designs for consistent quality in high-volume production.

Skiving

Skiving foam slices blocks into thin, uniform sheets for customization. In packaging, it provides lightweight padding for medical tools or retail goods, while in products, it supports cost efficiency by maximizing material usage and protection across diverse applications.

Die-Cut Foam

Die-cut foam employs specialized tools to stamp precise shapes in packaging and products. In packaging, it creates snug inserts for electronics, tools, glassware, and more. For products, it ensures consistent, durable designs for efficient high-volume production.

Straight Cut Foam

Straight-cut foam produces clean, uniform blocks for versatile use. In packaging, it offers sturdy padding for heavy industrial equipment or consumer goods, while in products, it ensures consistent surfaces for cost-effective manufacturing and minimal waste.

Gluing

Gluing foam together creates complex shapes for an almost limitless variety of custom products and packaging. It designs multi-layered inserts for electronics or aerospace parts, providing enhanced cushioning and durability for long-term use or repeated handling.

Sewing

Our in-house sewers craft custom fabric covers or cases, enhancing foam packaging for medical tools or retail goods. In products, it’s often the protective layer for the foam, ensuring a professional finish across industries.

Compression Roll

Compression rolling compacts foam products and packaging, significantly reducing their volume for efficient shipping and storage, which leads to substantial cost savings. This technique is perfect for large-scale production runs, allowing businesses to transport more foam in less space.

PRODUCT

Tailored Foam Solutions for Product Manufacturing

We provide expert foam solutions designed to enhance your manufacturing projects across various industries. From convoluted foam for mattresses and cushioning to advanced CNC-cut parts for complex components, our capabilities ensure every piece meets your specifications with precision and performance.

PACKAGING

When "Handle With Care" Simply Isn't Enough

Our foam packaging solutions offer reliable, cost-effective protection for your products. From die-cut inserts for electronics and tools to skived layers for delicate item separation, every design is crafted with precision. Whether you’re handling small batches or large-scale production, our custom foam options reduce transit risks and enhance the shipping experience for your business.

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WHO WE ARE

AF One MFG. Inc.

Operating out of Brampton, Ontario, we’ve been in business for decades, designing tailored foam solutions that ensure comfort, safety, and top-notch performance for all your product and packaging demands, no matter the application.

ISO 9001 Certified

Tailored Expertise

Fast & Efficient Delivery

Industries We Service

Our custom foam products and packaging solutions protect, enhance, and support operations across diverse industries, delivering precision, durability, and tailored cost savings to meet your unique needs and challenges, big or small, with unmatched reliability.

Consumer Goods and Retail

Our foam fabrication creates custom products for optimal performance while providing packaging that ensures fragile or high-end retail goods are safely delivered and stored.

Electronics and Technology

Anti-static foam products and packaging shield electronics from shocks, vibrations, and drops, ensuring safe handling and reliable performance.

Automotive and Transportation

Precision-crafted foam products and packaging safeguard automotive parts, ensuring damage-free transport, seamless assembly, and optimal performance.

Medical and Healthcare

Our contoured foam products and packaging safeguard delicate medical tools, ensuring safe storage and delivery. ISO Certified for guaranteed quality, sanitation, and peace of mind.

Aerospace and Defense

High-grade foam products and packaging defend aerospace components from impacts, ensuring precision and reliability under demanding conditions.

Industrial Manufacturing

Durable foam products and packaging fortify heavy industrial gear, protecting against impacts and ensuring resilience in both shipping and production.

…and much more!

Process

How It Works

Get custom foam products and packaging quickly through our streamlined design process, crafted with precision to meet your needs. Proudly made in Canada, we deliver reliable, cost-effective solutions, saving time and resources while avoiding overseas shipping challenges.

1. Submit Your Project Needs

Start by filling out our contact form with your project details—product dimensions, shipping needs, or unique requirements.

Whether it’s a small local order or a large-scale run, we’ll review your ideas and reach out to discuss how we can help protect your goods effectively and affordably.

2. Collaborate on Design

Our team collaborates with you to shape your vision, recommending foam types and options like convoluted or CNC-cut for both custom products and packaging. We’ll create a tailored solution that ensure precision, durability, and a secure fit, protecting your items while aligning with your budget goals.

3. Approve the Plan

You’ll receive a detailed proposal with design specs, timelines, and costs—no surprises, just clarity. Once you approve, we lock in the plan, ensuring your unique product or packaging requirements are set for production with precision and care tailored to your industry.

4. Craft Your Foam

At our Brampton facility, we craft your foam products and packaging using advanced techniques like die-cutting, skiving, sewing, gluing, and more.

Our ISO-certified process ensures quality, delivering durable solutions that protect your goods during shipping and support reusability for long-term use, whether for large, long-term production projects or small, short-term runs.

5. Receive Your Solution

We ship your custom foam packaging directly to you, tested for reliability and ready to use. From delicate electronics to heavy industrial parts, your products arrive intact, saving you money on returns and keeping your customers happy with every delivery.

Your Trusted Foam Manufacturing Partner for Products & Packaging

Home of Quality Canadian Brands for Over 30 Years

FOR CAREGIVERS

Orthopedic Comfort & Support

FOR KIDS

Excite Your Child's Imagination

FOR EVERYONE

The Mattress That Keeps Its Shape

CAPABILITIES

Industry Leading Equipment For Endless Foam Possibilities

Convoluted Foam

CNC Cut Foam

Skiving

Die-Cut Foam

Straight Cut Foam

Gluing

Sewing

Compression Roll

PRODUCT

Tailored Foam Solutions for Product Manufacturing

PACKAGING

When "Handle With Care" Simply Isn't Enough

WHO WE ARE

AF One MFG. Inc.

Industries We Service

Consumer Goods and Retail

Electronics and Technology

Automotive and Transportation

Medical and Healthcare

Aerospace and Defense

Industrial Manufacturing

Process

How It Works

GET IN TOUCH

Your Reliable Partnership Awaits