Custom Foam Manufacturing
Precision-cut EPS and XPS products to your exact specifications using advanced CNC and hot-wire technology.
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Engineering Foam Solutions for a Sustainable Future
From insulation to construction, packaging to architecture — we manufacture precision-engineered polystyrene products trusted across Australia.
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Four Decades of Foam Innovation
Established in 1982, Hispatian Foam Solutions has grown into one of Australia's foremost manufacturers of expanded and extruded polystyrene products. Our facilities span five states, employing over 250 skilled professionals dedicated to quality and sustainability.
We combine deep materials science expertise with modern manufacturing processes to deliver foam products that meet the exacting demands of construction, insulation, cold chain logistics and architectural design.
Discover Our StoryWhat We Deliver
Comprehensive foam and polystyrene solutions tailored to your project requirements
Polystyrene Insulation
High-performance underfloor, wall and roof insulation systems that improve energy ratings and reduce bills.
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Architectural Mouldings
Lightweight decorative facades, cornices, columns and custom shapes that replicate traditional materials at a fraction of the weight.
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Packaging Solutions
Protective EPS packaging, cold chain boxes and custom moulded inserts for safe transport of sensitive goods.
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Recycling Programs
Closed-loop recycling initiatives that recover and repurpose polystyrene waste into new products.
Learn more →The Hispatian Difference
Why leading builders, architects and brands partner with us
Australian Made
All products manufactured locally across our five state-of-the-art facilities, ensuring quality control and fast turnaround.
40+ Years Experience
Decades of materials science expertise and continuous innovation in foam engineering since 1982.
Sustainability Focus
Industry-leading recycling programs and lightweight materials that reduce carbon footprint in construction.
Custom Engineering
Bespoke foam solutions designed and manufactured to your exact specifications, from concept to delivery.
What Our Clients Say
Trusted by builders, architects and industry professionals nationwide
“Hispatian delivered custom waffle pods for our residential development three days ahead of schedule. The consistency and compressive strength exceeded our engineer's requirements.”Marcus Ellwood — Project Manager, Ellwood Construction
“We switched to Hispatian's XPS insulation boards last year and have seen measurable improvements in the energy ratings of our builds. Their technical support is outstanding.”Sarah Thornton — Director, Thornton Architecture
“The cold chain packaging solution they designed for our meal delivery service reduced transit damage by over 60%. Professional team from start to finish.”David Ling — Operations Lead, FreshBox Meals
Latest from Our Blog
Industry insights, product guides and sustainability news
EPS vs XPS Insulation: Which Is Right for Your Build?
A detailed comparison of expanded and extruded polystyrene for residential and commercial insulation projects.
Why Underfloor Insulation Matters More Than You Think
How rigid polystyrene underfloor panels can cut heating costs and improve comfort year-round.
Building Green: Polystyrene's Role in Sustainable Construction
Exploring how modern EPS and XPS contribute to energy-efficient, environmentally responsible buildings.
Common Questions
Answers to frequently asked questions about our foam products and services
EPS (Expanded Polystyrene) is manufactured by expanding polystyrene beads and fusing them together, resulting in a lightweight, cost-effective material. XPS (Extruded Polystyrene) is produced through a continuous extrusion process, yielding a denser board with higher compressive strength and lower moisture absorption. The best choice depends on your application — EPS is ideal for general insulation and void fill, while XPS excels in high-moisture or load-bearing environments.
Absolutely. Our facilities are equipped with CNC routers, hot-wire cutters and moulding systems capable of producing virtually any shape, profile or dimension. Whether you need architectural features, bespoke packaging inserts or engineered construction components, we can manufacture to your specifications with tight tolerances.
Modern polystyrene is 98% air by volume, making it an extremely resource-efficient material. It is fully recyclable, and our closed-loop recycling programs ensure production off-cuts and post-consumer waste are recovered and reprocessed into new products. Additionally, polystyrene insulation reduces a building's energy consumption over its lifetime, delivering a net positive environmental impact.
Our EPS panels achieve R-values ranging from R1.0 to R4.0 depending on thickness and density. Our XPS boards deliver R1.5 to R5.0 per standard thickness. We can recommend the ideal product and thickness to meet or exceed the National Construction Code energy efficiency requirements for your climate zone.
Yes. With manufacturing facilities in Victoria, New South Wales, Queensland, South Australia and Tasmania, we can fulfil orders across the country with competitive freight rates and fast lead times. We also offer project logistics support for large-scale construction deliveries.
Simply reach out via our contact page with your project details — including required product type, dimensions, quantities and delivery location. Our team will prepare a detailed quotation and can also provide technical guidance to ensure you select the optimal product for your application.
Ready to Start Your Project?
Get in touch with our team for expert advice, custom quotes, and fast turnaround on foam and polystyrene products.
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