Polyethylene Foam

Blocks of polyethylene foam

PE foam is closed cell foam made from polyethylene and blended copolymers. It has a high level of chemical cross-linking. The result is a smooth fine-cell foam sheet suitable for many situations. The benefits of Polyethylene foam include:

  • Impact and vibration absorption
  • Weather and chemical resistance including splash resistance to oils and fuels
  • Acoustic and thermal insulation properties
  • Buoyancy with low water absorption
  • Suitability for thermo-forming and thermo-moulding

More About Polyethylene Foam

Polyethylene can be supplied in various colours

Polyethylene is similar to EVA; however, it is a firmer product with a better compression set and greater resistance to heat. Importantly, PE foam is more cost-effective than EVA. It’s also available in thicker sheets and a range of density from 30 to 250 kg/m3.

Polyethylene Foam is formed in a mould, resulting in a sheet of foam known as a bun. The maximum length, width and thickness vary depending on the foam density. We can provide sheets, blocks or strips. Additionally, we can fabricate the foam into shapes and profiles.

PE Foam Density & Sheet Size Chart

Product – DensitySheet SizeMax Thickness
PE30 – 30kg/m32400 x 1200mm100mm
PE40 – 40kg/m32400 x 1200mm100mm
PE60 – 60kg/m32400 x 1200mm100mm
PE80 – 80kg/m32000 x 1000mm90mm
PE120 – 120kg/m32000 x 1000mm50mm
PE180 – 180kg/m31090 x 970mm20mm
PE250 – 250kg/m31000 x 890mm25mm
Polyethylene foam cut into complex shapes

PE foam is a versatile closed cell foam suiting a range of applications. It’s an effective replacement for many materials including felt, neoprene, natural rubber, polyurethane foam, PVC foam, wood composites, mineral wool and fibreglass.

Our customer Summit Gear uses PE foam for hip and shoulder padding in the hiking packs they manufacture. Another example is Techpack Solutions, who create engineered packaging solutions and case inserts from polyethylene foam.


  • Gaskets
  • Vibration Pads

Entertainment Industry

  • Costume Creation
  • Cosplay
  • Set and props


  • Gaskets and Seals
  • Carpet Underlay
  • Headliners
  • Interior Padding


  • Nail Washers
  • Expansion Joints
  • Glazing Seals
  • Eaves Fillers
  • Impact Sound Deflect
  • Insulation


  • Deck Tread
  • Life Jackets
  • Life Buoys
  • Fenders
  • Oil Boom Floats
  • Cockpit Cushions


  • Work Station Mats
  • Shock Absorbing Pads

Health Care

  • Splinting
  • Cervical Collars
  • Orthopaedic Shoes
  • Insoles
  • Exercise Mats
  • Orthotic Supports


  • Cushion Packaging Foam
  • Corner Pads
  • Case Inserts
  • Display Packaging Foam

Sports & Leisure

  • Trampoline Pads
  • Buoyancy Aids
  • Kickboards
  • Sports Mats
  • Body Protection
  • Canoe Seats
  • Toys and Games
  • Camping Bedrolls


  • Wedge Soles
  • Runner
  • Top Line Padding
  • Moulded Soles
  • Orthotics


Detailed specifications and test data for our range of Polyethylene foam.

Contact Us

Send an email and let’s discuss your project. We’ll suggest appropriate material and provide samples and a competitive quote.

Other Foam Products

Other products to consider include our range of EVA Foam and Ethafoam.


Safety data for our range of Polyethylene foam.

Metro Foam is on-site at Wetherill Park until 3:00 PM on Tuesdays, Wednesdays and Thursdays. Get in touch any weekday by telephone and email.