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Medical Foam Solutions
Precision cut, cleanroom-ready foam components for medical devices and packaging.
Janco Medical delivers custom medical foam solutions using premium closed-cell polyethylene materials, including Zote and Volara foams. These foams are selected for their biocompatibility, non-particulate performance, durability, and compatibility with sterilization.
Our team supports projects from material selection through manufacturing and packaging, ensuring each foam part meets FDA and ISO requirements for medical use.
With over 60 years of experience, Janco provides medical foam products engineered for protection, cushioning, stability, and precise fit within medical trays, orthopedic devices, and sterile packaging systems.
Our Medical Foam Capabilities
Janco engineers medical grade foams for trays, inserts, and packaging that require controlled contact, repeatable performance, and compatibility with sterile processing. Our closed cell polyethylene and specialty medical foams provide:
- Stable, non-shedding surfaces that prevent particulate transfer onto devices
- Moisture-resistant construction that supports sterilization requirements and prevents absorption of fluids during handling
- Energy-absorbing structure that protects delicate devices from vibration and impact during shipping and reprocessing
- Consistent density for predictable device seating and repeatable tray kitting
- Lightweight, durable composition that maintains geometry through sterilization, transport, and routine handling
Why Zote and Volara Foams
Zote is regarded as one of the highest performing medical foams available. Because it is chemically cross-linked, it has a durable closed- cell structure that delivers practical advantages for device protection,
Including:
- Smooth, uniform surface finish that will not abrade device surfaces
- High resistance to tearing, chemicals, and temperature changes so cavities keep their shape through sterilization and transport
- Excellent moldability for compression molding or die cutting, supporting precise, repeatable geometry
- Compatibility with common sterilization methods such as gamma and EO without loss of integrity
- Consistent cushioning that protects delicate and high-value instruments from impact and vibration
- Clean, non-particulate performance suitable for Class 7 and Class 8 cleanrooms
Volara is a cross-linked polyolefin foam recognized for reliable, high- quality performance in medical packaging. Its material properties translate into clear benefits, including:
- Consistent density and smooth surfaces for repeatable device seating and kit assembly
- Chemical resistance and low water absorption that support sterilization and long-term storage
- Non-particulate behavior appropriate for cleanroom use and sterile- barrier packaging
- Flexible, easily converted sheets that can be thermoformed, laminated, or die cut for complex layouts
- FDA-compliant, non-toxic composition suitable for medical packaging and device support
Janco maintains both Zote and Volara foams in stock in multiple densities and thicknesses. That gives customers dependable access to material for both cost-conscious projects and premium medical applications, and supports fast lead times and stable supply.
Medical-grade foams offer a combination of protection, cleanliness, and manufacturing flexibility that makes them ideal for device packaging and support components. Key advantages include:
- Compatibility with common sterilization methods without breakdown of
structure or shedding - Cleanroom-suitable surfaces that minimize particulate transfer onto sensitive devices
- Lightweight but durable performance that reduces shipping costs while maintaining protection
- Resistance to moisture, chemicals, and temperature changes, supporting stable long-term storage
- Effective cushioning that absorbs vibration and impact during handling, transport, and reprocessing
- Versatile processing options, including die cutting, molding, lamination, and thermoforming, for precise geometry
- Consistent density and firmness for device seating and repeatable kit assembly
- Custom shaping for inserts, spacers, trays, and packaging systems designed around exact device dimensions
Janco produces foam components in controlled cleanroom environments
to support sterile workflows and device safety. Our manufacturing process is built around precision, repeatability, and compliance with medical standards.
Capabilities include:
- ISO 14644-1 Class 8 cleanroom production and Class 7 cleanroom packaging for contamination-controlled workflows
- Die cutting, compression molding, and thermoforming for accurate, repeatable geometries across simple or complex parts
- Lamination and multi-layer construction for added durability, structured support, or varied density needs
- Prototyping, design refinement, and validation testing aligned with ASTM, ISO, or customer-specific requirements
- Full material traceability back to lot numbers to support regulatory documentation and audits
Applications and Industries Served
Janco’s medical foam products are used across a wide range of medical markets, including:
- Medical device packaging
- Surgical and sterilization trays
- Orthopedic supports, braces, splints
- Diagnostic components
- Laboratory and pharmaceutical packaging
- Cardiology and vascular devices
- Endoscopy and respiratory components
- Protective packaging for implants and instruments
Foam inserts, spacers, cushioning blocks, and custom die cut components are engineered around your device geometry for exact fit and maximum protection.
Janco partners with medical manufacturers who need foam components that meet strict compliance, deliver reliable performance, and support sterile packaging workflows. With over 60 years in medical manufacturing, Janco brings:
- ISO 13485 certification and FDA registration
- Class 7 and Class 8 cleanroom manufacturing
- Rapid sourcing with Zote and Volara foams always in stock
- Full converting capabilities under one roof
- Material expertise for biocompatibility and sterilization
- Regulatory support including ASTM, ISO, and FDA validation testing
- A dedicated engineering team focused on efficiency and precision
In recent years, medical foam supply chains have seen unpredictable lead times, resin shortages, and workforce disruption. Janco maintains a proactive approach, expanding our on-hand inventory of Zote and more than 35 grades and thicknesses of Volara so customers aren’t affected by industry delays. This ensures stable sourcing, reliable timelines, and consistent availability for high volume, mid volume, or low volume programs.
Why Janco
Janco partners with medical manufacturers who need foam components that meet strict compliance, deliver reliable performance, and support sterile packaging workflows. With over 60 years in medical manufacturing, Janco brings:
- ISO 13485 certification and FDA registration
- Class 7 and Class 8 cleanroom manufacturing
- Rapid sourcing with Zote and Volara foams are always in stock
- Full converting capabilities under one roof
- Material expertise for biocompatibility and sterilization
- Regulatory support, including ASTM, ISO, and FDA validation testing
- A dedicated engineering team focused on efficiency and precision
In recent years, medical foam supply chains have seen unpredictable lead times, resin shortages, and workforce disruption. Janco maintains a proactive approach, expanding our on-hand inventory of Zote and more than 35 grades and thicknesses of Volara so customers aren’t affected by industry delays. This ensures stable sourcing, reliable timelines, and consistent availability for high volume, mid volume, or low volume programs.
Ready to begin your medical foam project?
Contact Janco Medical to request a quote or discuss how our closed-cell foam solutions can support your medical device, packaging, or orthopedic application.
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