Our History
From Local Beginnings to Global Impact
From our start in a rented 25,000-sq.-ft. facility to becoming a leader in the polyurethane industry, NCFI has been built on a foundation of innovation, dedication, and community. What started in 1964 has grown into a roaring business committed to advancing technology, supporting industries, and improving lives. Explore our timeline to see how our vision has shaped the past six decades, driven by a passion for excellence and the motivation to build a better future.
The 1960s
This decade marked the birth of NCFI Polyurethanes, founded by Dr. H.W. "Ace" Bradley, a former Manhattan Project chemist, and the Barnhardt family. When it was founded, NCFI was a raw material supplier producing synthetic foam blocks for the furniture and bedding industries. As pioneers in polyurethane foam production, NCFI quickly established itself as an innovator. Within just two years, the company outgrew its rented space. By the end of the decade, NCFI operated out of a 63,000-sq.-ft. facility, setting the stage for decades of leadership in foam technology.
- NCFI Polyurethanes was founded as a division of Barnhardt Manufacturing Company, led by Dr. H.W. Bradley and Jacob O. "Jake" Barnhardt, who served as research chemists developing and testing foam products.
- Dr. Bradley was named the company’s first president.
- The company introduced and perfected the groundbreaking "One-Shot" production method, which became the U.S. flexible polyurethane foam (FPF) industry standard.
The 1970s
NCFI grew its operational footprint and solidified its reputation for innovation in foam technology. The decade was marked by the development of trailblazing products that fueled the company's growth across industries and spurred major plant expansions. Before the end of the decade, NCFI added 105,000 square feet of manufacturing and warehousing space in its home base of Mount Airy.
- NCFI focused on the growth of flexible foam fabrication by expanding its facilities to house new equipment and support future development.
The 1980s
The 1980s saw NCFI's rapid growth and technological advances, including a partnership with NASA for the Space Shuttle program. This decade demonstrated NCFI's versatility, with innovations spanning aerospace, geotechnical, and consumer applications. To support these advancements, NCFI increased its facility size to over 300,000 square feet by expanding the Mount Airy campus, opening a manufacturing facility in Ocala, FL, and acquiring Dalton Foam, Inc.
- NASA selected NCFI to supply foam insulation for the Space Shuttle program, which began with the first launch in 1981.
- The company began collaborating with Lockheed Martin, providing foam for the U.S. Space Shuttle's External Tank Program.
- NCFI became the first to develop poured and sprayed-in-place foam for geotechnical applications.
The 1990s
The last decade before the new millennium exhibited NCFI's leap into international markets and significant advancements in foam technology. With a growing reputation for technical excellence and global reach, the company set its sights on broader applications and opportunities, such as expanding the development of polyurethanes for concrete lifting and void-filling applications.
- NCFI shipped foam to Russia for the first time, adding to an international client base that already included Canada, South America, and Mexico.
The 2000s
The 2000s marked a new era for NCFI. This decade was defined by the company’s commitment to environmental stewardship and groundbreaking product innovations. From sustainable foam solutions to award-winning advancements, NCFI solidified its position as a leader in polyurethane technology. By the end of the decade, NCFI operated over 400,000 square feet of facility space, reflecting its growing popularity and innovation.
- NCFI became the first North American supplier to commercially offer hydrocarbon- and HFC-formulated rigid spray systems as alternatives to HCFC-141b.
- The company branded and marketed its SPF insulation formulations, which it had been producing and selling for years, leading to the launch of InsulStar.
The 2010s
From groundbreaking partnerships to sustainable innovations, the decade underscored the company's influence across industries and geographies. By the middle of the 2010s, NCFI became one of the last SPF systems houses. The decade concluded with the beginning of the construction of the “most advanced manufacturing facility in the industry” in Houston, TX.
- NCFI was honored by the U.S. Space Shuttle program with the Supplier Quality Excellence Award for its work on the External Tank Program with Lockheed Martin.
- The Consumer Products Division introduced Bio-Lux™ Max foams containing as much as 33% renewable content, the highest percentage in the market.
The 2020s
Despite global challenges, the 2020s demonstrated NCFI's resilience and focus on innovation. Significant investments in sustainability, cutting-edge manufacturing, and low-GWP foam solutions positioned the company for continued success.
- NCFI launched hydrofluoroolefin (HFO)-based foam products in the Construction Foam Division. These products featured low Global Warming Potential (GWP) and allowed for an increase in the maximum thickness of each layer, or “lift.”