Choosing the Right FOAM: What is the difference in various materials?
Why Foam Matters in Shipping
During transit, packages are exposed to drops, vibration, compression, and temperature changes. Foam absorbs shock, limits movement, and distributes pressure evenly around a product. The right foam can:
Prevent impact damage from drops and handling
Reduce vibration during long-distance transport
Protect fragile surfaces from scratches and abrasion
Improve unboxing presentation and perceived quality
The wrong foam, however, can compress too easily, crumble, or fail to protect at critical impact points..
Common Types of Foam Used in Packaging
1. Polyethylene (PE) Foam
Best for: Heavy items, repeated shipments, industrial and medical equipment
PE foam is dense, durable, and resistant to moisture and chemicals. It absorbs shock well and retains its shape over time, making it ideal for reusable packaging.
Advantages:
Excellent impact protection
Closed-cell structure resists moisture
Long-lasting and reusable
Considerations:
Higher cost than softer foams
Less flexible for very delicate shapes unless custom-cut
2. Polyurethane (PU) Foam
Best for: Lightweight, fragile items like electronics or glassware
PU foam is soft and flexible, often used in “egg-crate” or convoluted designs to cradle delicate products.
Advantages:
Good cushioning for light items
Flexible and shape-conforming
Cost-effective for one-time shipments
Considerations:
Less durable over time
Absorbs moisture unless treated
Not ideal for heavy loads
3. Expanded Polystyrene (EPS)
Best for: Appliances, bulk shipments, and cost-sensitive packaging
EPS (commonly known as Styrofoam™) is lightweight and rigid, offering strong shock absorption for its weight.
Advantages:
Low cost
Excellent compression resistance
Lightweight for reduced shipping costs
Considerations:
Brittle and can crack
Limited reusability
Environmental concerns unless recycled properly
4. Cross-Linked Polyethylene (XLPE) Foam
Best for: High-value products and premium packaging
XLPE foam offers a smoother surface and improved strength compared to standard PE foam.
Advantages:
Superior shock absorption
Clean, professional appearance
Resistant to chemicals and moisture
Considerations:
Higher price point
Often requires custom fabrication