Global Product Solutions. U.S. Manufacturing Strength
HLJ combines domestic foam and polyester-fiber manufacturing with precision fabrication, global product development, sourcing, direct-import programs, packaging, and fulfillment. Helping leading brands bring quality products to market at scale.
Domestic Manufacturing. Global Capabilities.
HLJ brings together U.S. manufacturing strength and global product development expertise to support customers from concept through final delivery.
With more than 450,000 square feet of U.S. manufacturing and operational capacity, we provide foam and polyester fiber production, precision fabrication, sewing, filling, compression packaging, and fulfillment. Our global sourcing and direct import network expands these capabilities, allowing HLJ to develop the right supply solution for each product, program, and market.
The HLJ Foam Legacy: Heritage, Scale, and American Craftsmanship
Our story began in 1988 as Allied Aerofoam, with a commitment to dependable manufacturing, quality workmanship, and customer service. Today, HLJ combines American craftsmanship with modern technology across its operations in Tennessee and Missouri, producing foam, polyester fiber, fabricated components, protective packaging, and finished consumer products for national brands and major retailers.
In 2020, we became HLJ Foam, reflecting the expansion of our manufacturing capabilities, product categories, and the markets we serve. The 2025 acquisition of Arlee Home Fashions further expanded our product-development, design, sourcing, textile, and home-furnishings capabilities, strengthening our ability to support customers across a broader range of consumer-product categories.
Today, we bring product development, domestic manufacturing, global sourcing, direct-import programs, packaging, and logistics together under one experienced leadership team. This integrated approach gives customers one dependable partner capable of managing complex programs from initial concept through final delivery.
Trusted by Industry Leaders
For decades, leading retail, home-furnishings, pet, industrial, and commercial brands have trusted HLJ to manufacture and deliver products at scale. From foam and polyester-fiber components to mattresses, comfort seating, pet products, protective packaging, and modular furniture, we support a wide range of programs with consistent quality, responsive service, and the flexibility to grow alongside our customers.
Services & Capabilities
U.S. Based product design and development supported by integrated domestic manufacturing and global production capabilities.
HLJ’s product design and development are led by our experienced U.S.-based teams, working closely with customers to transform initial concepts into production ready products. Our domestic capabilities include foam and polyester-fiber production, precision fabrication, sewing, filling, compression packaging, product assembly, and fulfillment.
Our U.S. operations are complemented by global sourcing and direct import capabilities. This flexibility allows us to develop the right solution for each program whether it requires domestic production, global manufacturing, or a combination of both. Based on the customer’s specifications, volume, cost, and delivery requirements.
HLJ Foam Packaging
Industries We Serve
From the living room to the dog bed to the retail floor. Trusted by professional foam manufacturers and fabricators to deliver safety and comfort across the categories families live with every day.
Our reach into diverse industries didn’t happen by accident. It grew from a simple, reliable ability: making high-quality foam products in the USA, at scale, for brands that cannot afford to compromise. That capability has integrated naturally into home goods, pet products, automotive interiors, and defense applications: Pottery Barn, Nike, and premium retail partners across categories. When leading retail partners need domestic production they can count on, they come here.
Military
Drones
Electronics
Appliances
Home & Furniture
Pet Products
Beauty & Wellness
Automotive & Marine
Industrial Protective Packaging
Custom & Specialized
Featured Products
HLJ Foam has been manufacturing custom foam and fill solutions for over 3 decades, building relationships with consumer brands and commercial clients who need reliable, repeatable results.
We produce everything from memory foam toppers to precision-cut inserts and custom packaging, all made to specifications, on schedule, and built to perform exactly as designed. Our product range includes Anywhere Chairs™, modular classroom furniture, and embroidered lifestyle accessories.
Our dog beds are designed to support pets of all sizes with high-quality memory foam that holds its shape over time.
We manufacture foam-based components for globally recognized brands like Nike, meeting strict quality and performance standards while delivering at scale.
Soft, durable, and made to last. These are designed for real life, protecting furniture while still feeling comfortable and premium.
Our Manufacturing Excellence
Over three decades of foam products made in the USA, for premium retail, direct to consumer, and everything in between.
At HLJ Foam, we’ve spent decades perfecting the art of foam fabrication. We don’t just run heavy equipment; we understand how different materials behave and what makes products perform reliably over time. As one of North America’s largest independent foam fabricators, we’ve built facilities that combine hands-on expertise with advanced cutting technology, including CNC routing, water-jet cutting, and compression molding.
Our team integrates Barudan embroidery systems, SmartHead laser tracing, and servo-driven precision tools to finish and personalize foam products at scale. Whether we are producing complex industrial components or soft consumer goods, our in-house team treats every project like it matters, because to the companies who rely on us, it does.
We are CertiPUR-US® Certified
Our facilities adhere to strict quality and safety standards to ensure every product meets performance expectations. We prioritize integrity in our foam solutions and maintain full compliance across consumer, industrial, and government sectors. Our products proudly feature CertiPUR-US® certified foams, ensuring low emissions and materials made entirely without harmful chemicals.