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Foam sheets are flat, cut lengths of foam used across packaging, construction, crafts and upholstery. They come in several types, each with its own properties and applications, and understanding these differences helps you choose the right product for your needs.
| Foam Type | Key Properties | Typical Uses |
|---|---|---|
| Polyurethane | Flexible, durable, good cushioning; easy to cut and shape | Upholstery, bedding, packaging |
| Polyethylene | Excellent shock absorption; water and chemical resistant; lightweight | Protective packaging, damp or outdoor applications |
| Polystyrene | Excellent thermal insulation; rigid and lightweight | Construction insulation, packaging |
The type of foam sheet used greatly affects the final product’s performance, so it is important to understand the options available. The most common types are polyurethane, polyethylene and polystyrene foam sheets.
Polyurethane foam sheets are known for their flexibility and durability. They are often used in upholstery, bedding and packaging because they provide excellent cushioning.
They can be easily cut and shaped, making them highly versatile and adaptable to a wide range of uses.
Polyethylene foam sheets are a closed-cell foam known for their excellent shock absorption and insulation properties, making them ideal for packaging and protection.
They are resistant to water and many chemicals, making them suitable for damp and outdoor applications. They are also lightweight and flexible, so they are easy to handle and install.
Polystyrene foam sheets (sometimes referred to by the brand name Styrofoam) are known for their excellent insulation properties. They are often used in construction and packaging because they resist heat transfer.
They are lightweight and easy to cut and shape. However, they are rigid and less durable than other types of foam sheet, making them less suitable for applications that need flexibility or long-term resilience.
Common properties of foam sheets include flexibility, durability, insulation and shock absorption, although these vary with the type of foam. Our foam properties overview explains how cell structure and chemistry affect performance.
Flexibility is the ability of a foam sheet to bend or deform without breaking. It is crucial in upholstery and bedding, where the foam needs to conform to the shape of the person or object using it. Polyurethane foam sheets are highly flexible, while polystyrene sheets are rigid.
Durability is the ability of a foam sheet to withstand wear and tear over time, which matters most under heavy use or in harsh conditions. Polyurethane foam sheets are generally more durable than polystyrene sheets. See our guide to foam durability for what makes foam last.
Insulation is the ability of a foam sheet to resist heat transfer, which is important in construction and temperature-sensitive packaging. Polystyrene foam sheets offer excellent insulation, while flexible polyurethane foam sheets offer moderate insulation. See our foam insulation guide for more.
Shock absorption is the ability of a foam sheet to absorb impact and protect the object it surrounds, which is crucial in packaging goods for transport. Polyethylene foam sheets offer excellent shock absorption, while polystyrene sheets offer moderate protection.
The manufacturing process varies by foam type, but the basic steps are preparing the raw materials, forming the foam, curing it, and cutting it into sheets. The steps below describe polyurethane foam; our foam manufacturing guide covers the process in more detail.
The base chemicals (polyols, isocyanates and other additives, depending on the foam being produced) are carefully measured and mixed to ensure the correct chemical reaction.
The chemicals react, generating their own heat, and the liquid mixture rapidly expands into foam. The foam is allowed to rise until it forms a large block, and the process is carefully controlled to achieve the correct density and consistency.
The foam is then left to cure, as the chemical reaction completes and the foam hardens and sets. Curing is crucial in determining the final properties of the foam, such as its flexibility, durability and insulation performance.
Finally, the cured foam is cut into sheets of the required thickness, size and shape using specialist cutting machinery, then inspected for quality and packaged. Learn more in our guides to foam cutting and foam blocks.
Thanks to their flexibility, durability, insulation and shock absorption, foam sheets are used in everything from packaging and construction to crafts and upholstery.
In foam packaging, foam sheets protect goods from damage in transit thanks to their shock absorption. They can be cut to fit the exact dimensions of the goods for a snug, secure fit, and their light weight keeps the overall package weight down.
Foam sheets are widely used in walls, roofs and floors to reduce heat transfer and improve energy efficiency. Some types are also used for soundproofing, as they help absorb sound and reduce noise transmission. Their light weight makes them easy to handle on site.
Flexible foam sheets are used in sofas, chairs, mattresses and pillows to provide comfort and support. They can be cut to fit the exact dimensions of the furniture or bedding item, and good-quality grades withstand heavy use for many years, making them ideal for custom cushions.
Foam sheets are also popular for crafts and DIY projects. They are easy to cut and shape, come in a variety of colours and textures, and are light enough to be easy to handle, even for children.
Foam sheets are a versatile material used across many industries. Each type has its own properties (from the cushioning of polyurethane and the shock absorption of polyethylene to the insulation of polystyrene), so understanding these differences will help you choose the right foam sheet for your needs.
Continue exploring foam formats, specifications and processes across our technical glossary:
Whether you need foam sheets for upholstery, packaging or a craft project, the Foam & Covers team can help you choose the right foam and cut it precisely to your measurements.
Contact Our Foam Specialists or Order Custom Cut Foam Online .
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