Where should I look for Foam suppliers/manufacturers for cushion/pillow foam?

I can help you with the exact need as I have previously worked, But prior to this, I need to understand what exactly are you looking for. Is it the market scenario, current players, contact info of key companies. I have a big list of all players along with profiles on each apart from the overall the global market condition. Contact me to know more..

If you have your CAD design done, you can get it printed in plastic first using inexpensive printers at 3DHubs for example. Do tweaks to the design and reprint. This can't cost more than $5 or so per print. Once you're happy you can then send your design to shapeways or i.materialise to be printed in metal. These services will likely charge a fee $100 for a metal print.

I am the founder of a cosmetic company that bootstrapped from nothing to a 7 figure business. It sounds like you are really at the beginning stages of business and there are a lot of opportunities for you. You've got a lot of work ahead of you and you need to build some infrastructure. Your brand is going to be one of the most important things to establish and you won't be able to sell to distributors, salons, or consumers without a clear message of what your company is about. When it comes to distribution of your product, you can either work with a distributor, sell directly to resellers, or sell directly to consumers. They all have their advantages and disadvantages. You'll have the most margin with direct to consumers - but you need skills on ecommerce. When you sell through a distributor you lose tons of control, but you can expand your reach quicker. You also have the slimmest margins; but you don't need to invest as much into sales. Selling direct to salons is a time consuming process; but you have more control of how your product is displayed, and the perception the consumer has of your products. So much of cosmetics is where your product is currently sold. If it's sold in mass market retail, no salon will want to carry it. But the direct answer of your question is you simply need to sell your product to anyone who's willing to buy it. Pick up the phone, hustle, and win over those customers.

http://makersrow.com - this is probably your best bet. I wouldn't use a website though. I'd talk to entrepreneurs and creators of high tech textiles in the USA. Look specifically at http://titintech.com and Klymit jacket. Reach out to those founders and learn as much as possible. Both of them are really nice guys and might be better equipped to share horror stories as well. Also be sure to look at http://reddit.com/r/textiles

I want to begin by assuring you I don't want to rain on your parade. Now... Ideas are a dime a dozen. Execution is what is critical, and hardly anyone does execution well. NDAs are nice but they won't protect your idea from being ripped off in the medium term at the latest, if it's a winner. Your best protection is that execution thing...people sure like to talk, but they don't like to Do. Do NOT have your prototype made in China. It will take months in shipping back and forth, misunderstandings, finding the right manufacturer, and other difficulties. Do not embroil yourself in that mess. Absolutely you should get a prototype made first. Will it cost you 10-100X what the final version will cost? Of course. Do you need something to show investors, suppliers, channel partners, retail outlets? Yes. All a patent does is protect your idea for awhile from being duplicated in the exact way you are executing it. I can't go make a sticky-note that uses a strip of lightweight glue to hold the paper onto something. 3M has that patent. But I could find another method for holding the paper on, and that would be fine. Worrying about protecting your idea is kind of a waste of time. You should do what you can afford and what makes sense in terms of your time invested to accomplish a level of protection, but don't let this be all-consuming. It's just not worth it. Get out there and make your product and find paths to market. That's what will really pay off. Someone WILL copy your product sooner or later if it's a money-maker. That's why developing great branding is so important: keep the knock-offs in the knock-off category in your buyer's brain, and you as the top quality original.