United States Two-Component Polyurethane Foam Market to Reach $2.6 Billion by 2031 at 7.4% CAGR, Powering the Future of High-Performance Insulation | DataM Intelligence

Leander, Texas and TOKYO, Japan - Nov. 17, 2025. According to DataM Intelligence, the United States Two-Component Polyurethane Foam Market is expected to reach USD 2.6 billion by 2031, advancing at a CAGR of 7.4% as energy-efficient construction and insulation upgrades accelerate nationwide. Growing pressure to meet U.S. Department of Energy efficiency targets, alongside rising demand for lightweight, high-performance materials, is strengthening the adoption of two-component polyurethane systems across residential, commercial, and industrial projects. These foams offer superior thermal insulation, air sealing, and structural support while complying with EPA low-GWP requirements and ICC building standards. With their ability to form durable, on-site rigid or flexible structures, they are increasingly used in spray insulation, roofing, retrofits, and automotive components, helping builders and manufacturers cut energy consumption and support America's broader net-zero goals.

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✅54 Figures
✅190 Pages of detailed insights and forecasts

Competitive Landscape

The market is highly competitive among global chemical leaders, foam manufacturers, and insulation specialists.

1️⃣BASF SE expanded its U.S. production of low-GWP two-component PU foams at its Geismar, Louisiana facility in Q2 2024, increasing capacity by 20% to serve residential construction clients with enhanced fire-resistant formulations.

2️⃣Dow Inc. acquired a specialty polyol supplier in Texas in early 2025, bolstering its North American portfolio and reporting a 16% revenue boost in spray foam segments through integrated sustainable resin technologies.

3️⃣Huntsman Corporation partnered with four U.S. automotive OEMs to develop lightweight two-component foams for EV battery enclosures, capturing 22% of the electric vehicle insulation market with 25% weight reduction benefits.

4️⃣Covestro AG introduced bio-based MDI variants for rigid foams in mid-2024, securing contracts with Midwest roofing firms and driving 19% growth in its U.S. commercial building
sales via recyclable content innovations.

5️⃣Lanxess AG rolled out high-density two-component systems for industrial packaging, cutting processing times by 28% and collaborating with Amazon for e-commerce cushioning solutions in high-volume U.S. distribution centers.

Recent Developments

1. BASF SE launched Elastospray PUREAIR technology, a low-GWP two-component spray foam compliant with U.S. EPA SNAP regulations, demonstrated at the International Builders' Show in Las Vegas (February 2024).

2. Dow Inc. opened a new R&D center in Freeport, Texas for two-component PU foam innovations targeting energy-efficient retrofits, focusing on open-cell applications for residential markets (May 2024).

3. Huntsman Corporation enhanced its Arathane line with AI-optimized mixing for automotive foams, piloted in Detroit facilities to improve vibration damping in EVs (August 2024).

4. Covestro AG debuted recyclable two-component slabstock foams for furniture at High Point Market in North Carolina, reducing virgin material use by 35% in U.S. manufacturing trials (October 2024).

5. Lanxess AG collaborated on bio-attributed polyols for two-component foams with U.S. suppliers, achieving 40% lower carbon footprint in construction pilots under California's green building standards (March 2025).

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Growth Drivers

✦ The U.S. construction industry exceeded USD 1.9 trillion in 2024, with insulation materials representing 7% of costs, spurring adoption of two-component foams for code-compliant thermal barriers amid housing shortages.

✦ Automotive output surpassed 10.5 million vehicles in 2024, demanding over 1 billion cubic feet of lightweight PU foams annually to meet CAFE standards and EV weight reduction targets.

✦ DOE energy codes injected USD 550 billion into efficient building upgrades by 2025, prioritizing two-component systems' R-value superiority for net-zero compliance in commercial retrofits.

✦ North American e-commerce logistics grew 25% post-2023, utilizing 750 million units of protective PU foam packaging yearly as supply chain resilience drives custom cushioning innovations.

✦ Formulation advancements reduced application waste by 26%, projecting USD 350 million in annual savings for U.S. installers by 2030 through precise on-site metering and spraying.

Market Segmentation Analysis

By Resin Type: The two component polyurethane foam market is segmented into MDI, TDI, and Others, with MDI leading at 60% share (USD 3.72 billion in 2023), projected to USD 6.42 billion by 2031 at 7.5% CAGR for rigid insulation durability. TDI holds USD 2.18 billion, growing to USD 3.76 billion at a 7.3% CAGR via flexible automotive uses. Others at 20% (USD 1.24 billion) will reach USD 2.14 billion, while the segment grows at 7.2% CAGR.

By Application: Spray Foam dominates with 50% share (USD 3.1 billion in 2023), expected to reach USD 5.35 billion by 2031 for on-site versatility. Slabstock at 30% (USD 1.86 billion) projects to USD 3.21 billion, supporting molded components. Others (20%, USD 1.24 billion) grow fastest at 7.6% CAGR to USD 2.14 billion, embracing pour-in-place innovations.

By End-User: Construction leads at 40% (USD 2.48 billion in 2023), growing to USD 4.28 billion by 2031 through roofing and wall demands. Automotive at 25% (USD 1.55 billion) reaches USD 2.68 billion for underbody protection. Furniture & Bedding (20%, USD 1.24 billion) enhances comfort; Packaging and Others (15%, USD 0.93 billion) scales for protective enclosures.

🌍Regional Insights

United States: The U.S. market was valued at USD 1.5 billion in 2023, projected to USD 2.6 billion by 2031 at a 7.4% CAGR, driven by DOE insulation mandates and EV growth under the Inflation Reduction Act. Over 65% of contractors adopted two-component systems since 2023 for efficiency in 11,000+ sites.

Canada: Canada's market, at USD 0.4 billion in 2023, grows to USD 0.67 billion by 2031 at a 7.4% CAGR, supported by the Net-Zero Emissions Accountability Act's CAD 2.5 billion for green building foams. BASF pilots cold-weather formulations; forecasts indicate 35% adoption rise and 22% cost cuts by 2027 via advanced spraying.

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Market Outlook and Opportunities: The Global Two component polyurethane foam market is at a tipping point, driven by DOE energy directives and every ounce of formulation evolution in high-performance insulators. Valued at USD 6.2 billion in 2023, it is projected to reach USD 10.7 billion by 2031 at a steady 7.4% CAGR. North America, holding over one-fifth of the global share, spearheads growth via construction rebounds, while the U.S. leverages automotive electrification. Advances in low-GWP and bio-based resins align with EPA sustainability targets, though challenges like raw material price swings, installer training gaps, and flammability regulations endure. Post-pandemic infrastructure investments and rising automation in dispensing equipment unlock vast opportunities for superior thermal management and productivity in construction, automotive, and packaging sectors.

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