The most commonly applied type of PE foam – non-cross-linked foam – owes its popularity to three factors.
The first is the low price, which is the direct consequence of the straightforward and cost-effective manufacturing process.
The second is low mechanical durability, which might seem a drawback, but turns to be beneficial in the context of packaging. The foam’s capability to compress quickly and permanently upon impact or substantial vibration (such as in transport) functions like vehicle crush zones and protects the (brittle and fragile) objects inside the packaging.
The third factor is thermal insulation. The dimensional stability in the range from -40°C to +95°C aligns perfectly with the thermal endurance requirements between a heat exchange system (in a boiler room) and heater (radiator).
This is why polyethylene foam is used to make the most popular pipe cladding in heating systems.
There is also a fourth factor: total and easy recyclability, which will only gain in prominence, as protection of the natural environment in scope of sustainable development is turning into a priority.

  Cross-linked PE foam is resilient and mechanically durable and finds application wherever there is demand for resistance to permanent deformation together with extensive durability and preservation of the fundamental parameters.
Due to their specifics, cross-linked foams come in form of cools (rolls) and blocks.
Foam rolls are available in physically cross-linked (with a smooth texture attributed to their uniformly small cell structure) and chemically cross-linked (with a rougher texture as the cells are larger with more irregular shapes and sizes) versions.
Before being released for further processing, chemically cross-linked foam blocks have their thick and hard ense, rigid outer layers removed to expose their structure.
Different foam types have different cellular structures. Certain ones are made up of small cells with thin walls, others are quite the opposite. The smooth ones have extremely small cells and find application in protection of fragile surfaces of the packed objects (specifically in transport). The ones with large cells are reflective and often used for purposes of packaging for exclusive products, jewellery and high-end beauty products.
The PE foam industry is working on developing non-cross-linked foam types exhibiting high mechanical durability. As they are supposed to be totally recyclable and have good mechanical properties, they will pose formidable competition for XPE foams. As they will be non-cross-linked, they will be easy to machine-process and cut and these processes will take less toll on the applied tools.

   The most popular polyethylene foam in the world is Plastazote®.
It owes its reputation to its exceptional properties and outstanding parameters achieved at relatively low densities.

In terms of hardness, elasticity, and stiffness, closed-cell polymer foams are ranked as follows (starting from the softest)

SI ; CR ; EPDM ; EVA ; PE ; PP ; PA *

PE foam application

Packaging – due to the desired mechanical properties and low weight
– transport filler (crates, baskets, containers) – stabilisation and protection in transport
– 3D transport separators (“combs”), transport system elements / dunnage
– toolbox inserts
– self-adhesive die cuts and seals
– foam spacers for protection in transport
– bottle and canister cap seals
– edge protectors for the furniture sector, construction joinery manufacturers, and other industries
Construction industry – thermal and acoustic insulation
– thermal insulation cladding
– ventilation duct insulation
– seals (fillers) for corrugated metal sheets and metal roof tiles
– acoustic and thermal insulation for concrete levelling
– underlayer for floor panels
Sports, tourism, and leisure – for resilience, cushioning, physical resistance, and excellent buoyancy
– athletic mats, tatami (for judo, karate, aikido, ju-jitsu), exercise (fitness) mats; camping mats / carrimats
– wall padding for sports facilities and gyms / „crash walls”
– protective padding for basketball backboards
– backpack frames
– swimming kickboards and pool accessories
The toy industry and learning aids sector – due to the smooth surface (this applies mainly to foam blocks), extensive selection of colours, and ease of keeping clean
– large blocks, puzzles, and puzzle mats for daycares, kindergartens, block playrooms, and playgrounds
– educational toys
– large (oversized) board games
Footwear and orthopaedics
– contoured (thermoformed, milled, and cut) and flat insoles
– shoe elements (legs / insteps and vamps; midsoles)
– shoe collar padding
– orthopaedic wedges
– pads
Rehabilitation
– rehabilitation mats and rollers
– movement rehabilitation aids
– development and rehabilitation blocks
Yacht industry
– buoyancy and structural components
– upholstered elements
Military equipment and uniforms
– body protectors
– weapon case inserts
– holsters
Protective OHS equipment
– knee protectors / knee pads
– protective glove elements
– protective face shield elements
Raised embroidery
– decorative embroidery
– embroidered military insignia

PE foam processing

– heat sealing / laminating (to form multilayer material)
– butt welding (to increase the flat sheet dimension)
– splitting – cutting to desired thickness
– cutting and machine processing (multi-axis CNC machining)
– thermoforming
– bonding

Attention:
Adhesion of polyethylene foams requires dedicated adhesives because of the material’s extremely low surface tension. Treatments such as corona or primer application may be very helpful.

Polting Foam offers the following types of PE foams:
– sheets (blocks) approx. 2 m x 1 m; thickness 30-105 mm
– coils / rolls; thickness 0.8 mm-15 mm
– laminates (multiple layer materials); thickness up to 500 mm
– thin sheets (as thin as under 1 mm)
– 2D and 3D die cuts
– thermoformed elements
– self-adhering

*
SI – Silicone
CR – Chloroprene Rubber – neoprene
EPDM – Ethylene propylene diene monomer
EVA – Ethylene-vinyl acetate
PE – Polyethylene
PP – Polypropylene
PA – Polyamide – nylon

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