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Foam packaging is a lightweight, protective material used to cushion products during shipping and storage. It is made from several types of foam (most commonly polyurethane, polystyrene and polyethylene), and this guide covers their characteristics, applications and how they are made.
Foam packaging is popular because it is lightweight (helping to reduce shipping costs), provides excellent cushioning and can be tailored to fit a specific product. Understanding the different types of foam will help you choose the most suitable option for your packaging needs.
| Foam Type | Cell Structure | Key Properties | Best For |
|---|---|---|---|
| Polyurethane | Flexible, open-cell | Lightweight, excellent shock absorption, easy to cut and shape | Cushioning fragile items with a snug fit |
| Polystyrene (EPS / XPS) | Rigid, closed-cell | Lightweight, excellent insulation, moisture-resistant | Temperature-sensitive products |
| Polyethylene | Flexible, closed-cell | Excellent shock absorption; resistant to moisture and chemicals | Protecting products in transit, damp conditions |
Several types of foam are used in packaging, each suited to different applications. The right choice depends on the weight, size and fragility of the product being packaged. The most common are polyurethane, polystyrene and polyethylene foam.
Polyurethane foam is a flexible, open-cell foam often used for cushioning in packaging. It is lightweight and has excellent shock absorption, making it ideal for protecting fragile items. It can be easily cut and shaped to fit a product’s exact dimensions for a snug, secure fit.
There are different types of polyurethane foam, including ester and ether grades. Ester polyurethane foam is generally firmer and tougher, making it suitable for heavier-duty applications, while ether polyurethane foam is typically softer and more flexible, making it well suited to delicate items.
Polystyrene foam (sometimes referred to by the brand name Styrofoam) is a rigid, closed-cell foam commonly used in packaging. It is lightweight and has excellent insulating properties, making it ideal for shipping temperature-sensitive products. It is also resistant to moisture, providing additional protection.
Polystyrene foam comes in several forms, including expanded polystyrene (EPS) and extruded polystyrene (XPS). EPS is lighter and less expensive, making it a popular choice for packaging, while XPS is denser and stronger, making it suitable for heavier-duty applications.
Polyethylene foam is a flexible, closed-cell foam commonly used in packaging. It is lightweight and has excellent shock absorption, and it is resistant to moisture and many chemicals, providing additional protection for products.
Polyethylene foam is available in a range of densities. Lower-density grades are softer and more flexible, making them ideal for cushioning delicate items, while higher-density grades are firmer and suited to heavier-duty applications.
The characteristics of foam are largely determined by its chemical composition and manufacturing process, and can be adjusted to suit different applications. Key characteristics include density, compressibility, resilience and tensile strength. Our foam properties overview explains these in more detail.
Density is the mass of foam per unit volume. It affects the foam’s strength, durability and cushioning. Higher-density foams are typically stronger and more durable, making them suitable for heavy-duty applications, while lower-density foams are often softer and better suited to cushioning delicate items.
Manufacturers control density by adjusting the formulation and the conditions under which the foam is formed, producing a wide range of densities for different applications.
Compressibility is how much a foam compresses under a given load, and it has a direct effect on cushioning. Foams that compress readily under load can absorb more shock, making them ideal for protecting fragile items. Learn more in our guide to foam compression.
Resilience is how quickly a foam returns to its original shape after being compressed. Highly resilient foams maintain their shape and cushioning after repeated compression, making them ideal for packaging that needs to provide long-term or reusable protection.
Tensile strength is the maximum pulling stress a foam can withstand before breaking. It affects the foam’s durability and resistance to tearing, so foams with high tensile strength are suited to heavy-duty applications.
Compressibility, resilience and tensile strength can all be adjusted during manufacture to produce foams for different applications.
Foam is widely used in packaging, but it has many other uses too. Key applications include cushioning, insulation, flotation and sound absorption, each requiring foam with specific properties. See our foam applications guide for more examples.
Foam protects products from impact and vibration during shipping and storage, reducing the risk of damage. Cushioning foams are typically flexible, compressible and resilient.
The right foam depends on the product: delicate items may need a softer, more flexible foam, while heavy items may need a denser, more durable foam.
Foam is also used to protect products from temperature changes in transit. Insulating foams are typically rigid with low thermal conductivity, reducing heat transfer and helping to maintain a consistent temperature. Temperature-sensitive products need a foam with high insulating performance, while other products may not need insulation at all. See our foam insulation guide for more.
Foam is used for flotation in life jackets, buoyancy aids and other flotation devices, as it provides excellent buoyancy. Flotation foams are typically closed-cell with low water absorption, and the exact grade depends on the buoyancy and durability the application requires.
Foam is used in acoustic panels, soundproofing and noise reduction. Sound-absorbing foams are typically open-cell, reducing the amount of sound reflected and improving acoustics. Acoustic panels need a foam with high sound absorption, while soundproofing may require a denser, more durable foam.
Foam manufacturing involves preparing the raw materials, foaming, curing and cutting. The exact process depends on the type of foam and the properties required. Our foam manufacturing guide covers this in more detail.
The raw materials are carefully measured and mixed in the correct proportions. Polyurethane foam is made from polyols and isocyanates, while polystyrene foam is made from styrene and a blowing agent.
Gas is introduced into the mixture, creating bubbles that cause it to expand into foam. Polyurethane foam is typically foamed by a chemical reaction, while polystyrene foam is expanded using heat and pressure. The process is carefully controlled to achieve the desired properties.
The foam is then left to cure, hardening and stabilising. Curing affects the final density, compressibility, resilience and tensile strength of the foam. Polyurethane foam typically cures at room temperature, while expanded polystyrene is moulded with steam and then left to stabilise.
Finally, the foam is cut to the required shape and size. The method depends on the type of foam: flexible polyurethane foam is typically cut with blades or saws, while polystyrene foam is often cut with a hot wire. See our guide to foam cutting for more.
Foam packaging is a versatile, efficient way to protect products during shipping and storage. Whether you are packing delicate items that need soft, flexible foam or heavy items that need a dense, durable foam, understanding the different foam types and their characteristics will help you choose the right option and keep your products well protected.
Continue exploring foam types, formats and specifications across our technical glossary:
If you need foam cut to fit a case, box or product, the Foam & Covers team can help you choose a suitable foam and cut it precisely to your measurements.
Contact Our Foam Specialists or Order Custom Cut Foam Online .
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