4 June 2026 | Engineering, Events
Engineered Foam Products attended Futurebuild London to showcase how HVAC foam components made from EPS and EPP are helping manufacturers design lighter, thermally efficient and more design-flexible heating, ventilation and air-conditioning systems.
Engineered Foam Products (EFP) recently attended Futurebuild London at ExCeL, joining manufacturers, specifiers, designers and construction professionals exploring the future of the built environment.
Co-located with UK Construction Week, the event provided a valuable opportunity to showcase EFP’s long-standing expertise in HVAC foam components and demonstrate how expanded foam materials are supporting the development of lighter, more efficient and more sustainable building technologies.
With more than 30 years’ experience manufacturing components for the HVAC industry, EFP used the event to highlight the role of expanded polystyrene (EPS) and expanded polypropylene (EPP) in applications ranging from ducting and heat exchangers to housings, boiler components, underfloor heating, invisible piping, TEV and TCM parts.
Challenging Perceptions Around HVAC Foam Components
“One of the strongest themes from the show was the level of interest in the material itself,” says Tracie Waters, Head of Components at Engineered Foam Products.
A key part of EFP’s approach at Futurebuild was to bring the material to life through real customer applications. The team was pleased to be supported by two long-standing customers, Verplas Ltd and Vital Energi, who provided display products featuring EFP-manufactured components. These exhibits enabled visitors to see first-hand how engineered foam is already being used in innovative, commercially successful HVAC systems.
Visitors were naturally drawn to the HVAC samples on display, with many recognising the practical benefits of lightweight, thermally efficient moulded components within modern heating, ventilation and air-conditioning systems.
“The EPS ducting system we manufacture for Verplas Ltd helped show how expanded foams can bring real system benefits, including improved airflow efficiency, thermal performance, easier handling and faster installation when compared with more traditional material options. Lots of visitors gravitated towards the ducting display as it created real intrigue,” Tracie explains.
EFP also displayed a large EPP Heating Interface Unit (HIU) manufactured for Vital Energi, which demonstrated more complex moulding geometry and the integration of EPP with other materials.
“The HIU unit prompted some really interesting conversations around the material itself. Many visitors were surprised to learn it was moulded from EPP, as they hadn’t realised expanded foam could achieve that level of detail, complexity and finish. It certainly gave people food for thought,” says Tracie.
For EFP, that reaction captured one of the key reasons for attending Futurebuild: to help manufacturers, specifiers and design teams better understand what is possible with engineered foam materials and EFP’s foam moulding know-how.
Tracie Walters
Head of Components & HVAC Specialist
Tracie Walters leads EFP’s component sales activity and has 25 years’ experience supporting HVAC manufacturers with moulded EPS and EPP parts. Her expertise covers the practical use of engineered foam in heating, ventilation and air-conditioning applications, including ducting, housings, heat exchangers, boiler components and wider system parts.
Through close customer collaboration, Tracie helps manufacturers explore lighter, thermally efficient and more design-flexible alternatives to traditional materials.
Why EPS and EPP Matter in HVAC Design
As the construction and building services sectors continue to focus on energy efficiency, installation speed, weight reduction and long-term performance, material choice is becoming increasingly important.
Expanded foam HVAC components offer a combination of properties that make them well suited to modern system design. EPS and EPP can deliver excellent thermal insulation, high strength-to-weight performance, acoustic benefits and long-term durability, while helping manufacturers replace heavier, more complex or less efficient components.
For HVAC manufacturers, moulded foam components can support a number of practical benefits, including:
- improved thermal efficiency
- significant weight savings
- faster and easier installation
- reduced parts inventory
- sound deadening performance
- long service life
- design flexibility
- opportunities to use recyclable, resource-efficient materials
The ability to mould complex forms also opens up opportunities to integrate features directly into the component design. This can help reduce assembly complexity, support part identification and colour coding, improve branding opportunities and allow manufacturers to develop more efficient system designs.
EPP and EPS HVAC Components: More Than a Material
EFP’s presence at Futurebuild was also an opportunity to highlight the depth of capability behind the finished parts.
The company has been moulding components for the HVAC industry since the early 1990s and manufactures more than 45 air conditioning components for one customer alone. This long-standing experience means EFP is not only supplying moulded HVAC components, but supporting customers through design, product development, material selection and manufacturing.
Foam capabilities showcased at the event included:
- advanced surface texturing, etching and finishes
- multi-density moulding
- mould-in-situ integration
- part identification and colour coding
- branding and customisation
- EPS densities from 18–100g/l
- EPP densities from 18–80g/l
- full in-house design and technical support
This combination of material knowledge, tooling expertise and technical support allows EFP to work closely with HVAC manufacturers to develop moulded foam solutions that are practical, efficient and production-ready.
Supporting Smarter, More Efficient HVAC Systems
Futurebuild focuses on the future of the built environment, making it a fitting platform for conversations around the next generation of HVAC systems.
As building technologies evolve, there is growing demand for components that can help improve system performance while reducing unnecessary weight, complexity and waste. Expanded foam materials have an important role to play in that transition.
For EFP, the event reinforced the value of showing the physical possibilities of EPS and EPP. When visitors can see, handle and question the parts in person, it becomes easier to challenge assumptions about foam materials and open up new design conversations.
The response at Futurebuild showed strong interest in how HVAC foam components can support innovation across a diverse range of applications, from ducting and housings to heat exchangers, boiler components and more complex integrated system parts.
Looking Ahead
EFP’s attendance at Futurebuild London was a valuable opportunity to connect with existing customers, meet new prospects and demonstrate the role expanded foam can play in the future of HVAC system design.
The conversations on the stand highlighted both the practical benefits of EPS and EPP and the importance of helping manufacturers better understand the difference these materials can make in the market.
As the industry continues to look for smarter, lighter and more sustainable innovation, EFP is well placed to support HVAC manufacturers with the design, development and production of high-performance moulded foam components.
Ready to Explore HVAC Foam Components for Your Next Project?
Speak to Tracie to discuss your application, material options and requirements.
Whether you are exploring materials for a new HVAC component or a bespoke moulded foam solution, Engineered Foam Products can support your project from concept through to production.
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