PE Foam vs. EVA Foam: Which Should You Use?

What is the difference between materials like Polyethylene (PE) and Ethylene-Vinyl Acetate (EVA)? If you work in heavy-duty industries, you will likely come across these materials, especially in the manufacturing sector.

Due to their unique properties, closed-cell foams are popular in many industries, but you might be wondering what is best to use. This blog will be your ultimate guide and will be especially helpful when you start planning for your next project.

What Are The Characteristics of PE Foam?

PE stands for polyethylene, a popular plastic material available in large quantities, reasonably priced, and has a number of applications. Polyethylene also has different grades that are common in lightweightness and thermoplastic behaviour, and are adjustable.

Mainly used as a packaging material, extruded polyethylene foam has a closed-cell structure for good mechanical protection. Modifying the flat foam structure into a three-dimensional shape by thermoforming isn’t possible.

PE foam is widely used in protective packaging, providing cushioning for delicate items during transit. Its insulating properties also make it a preferred choice for thermal insulation in construction and refrigeration industries.

Closed-cell cross-linked PE foam

This PE foam is flexible and absorbs vibrations because it is a foaming material. With a 0.3 – 500mm thickness and a 0.025 – 0.350g/cm3 density, this material is up to 30 times lighter than water! Cross-linked foam forms a resistant surface, meaning that molecules connect by chemical bonds during the cross-linking process, forming a three-dimensional structure.

It is also available in conductive, fire retardant variants and can withstand all weather, does not react with most chemicals, has a high dampening effect, cannot be consumed by insects, and is not vapour permeable. Cross-linked PE foam is used to produce a durable insulating material. Where can the foam be used?

As a polyolefin insulation material in the automotive industry, mechanical engineering and architecture, due to good water, heat and sound insulation.
Used to make mattresses and shoe soles due to its absorbing and dampening effect.

Bio-based cross-linked polyethylene foam

Almost entirely made from raw material obtained from biomass (sugar cane), there are many advantages of this technology, such as:

It is high performing.
It is environmentally friendly to produce.
It is versatile and has applications similar to traditional PE foam.

The price of PE chemical foam is dependent on the foam thickness, foam density, shape and size, self-adhesive or non self-adhesive, fire resistance level, and colour.

Anti-Static PE Foam Sheet

Designed with toughness and flexibility, what are some of the features of this PE foam?

Great tear strength
Low water absorption
Excellent chemical resistance
Great UV properties
Free of heavy metals, plasticisers and CFCS
Designed for stringent packaging applications
Dust-free when cut and easy to fabricate
Density = 45kg/m3
Sheet size = 2100mm x 1100mm

Premium 3M Adhesive Backed EVA Marine Grade Foam Decking for example provides a resilient (yet comfortable) walking surface that handles any marine environment. This EVA foam is backed with 3D adhesive, stops mould growth, offers a stable surface underfoot, absorbs shocks and impacts, and is non-slip and safe to walk on.

To learn more about how thin foam sheets can work for you, have a read of the top benefits of using thin foam sheets for protecting fragile electronics.

What are the benefits of PE foam?

When compared to other foam materials, PE foam is often more affordable, making it a cost-effective solution for large-scale projects. They are easy to use in so many applications. PE foam is easily cut, shaped, and laminated, facilitating its use in packaging, insulation, and more.

Are there any limitations to PE foam?

While PE foam offers some level of impact resistance, it may not provide the same level of shock absorption as other materials like EVA foam. PE foam typically has a lower rebound rate, meaning it may not return to its original shape as quickly after compression, which can be a consideration in applications requiring frequent compression and decompression.

What is EVA Foam?

Ethylene-vinyl acetate (EVA) foam, also known as foam rubber, is a versatile foam material with a closed-cell structure. Combining the properties of ethylene and vinyl acetate. With a fine uniform cell structure that means it can be processed like other plastics, EVA is formed in a mould, which becomes a sheet of closed-cell foam. This “bun” is cut from sheets or fabricated into a specific shape or item per specification.

EVA foam has excellent shock absorption, moisture resistance, and resistance to chemicals, so it is a great choice for applications that require durable, flexible foam materials. Let’s take a quick look at the characteristics of EVA foam:

It is UV-resistant, so it can be used outdoors!
Flexible, it can easily be moulded into different shapes and sizes, and easily bounce back to its original shape.
In comparison to natural rubber, it has excellent cushioning properties and impact absorption (such as for sports equipment).
Is resistant to cracks and stress under all demanding conditions
Low water absorption. Being a closed-cell foam, water cannot penetrate its surface.
It has a high rebound, so it can rebound or recover quicker than other foams.
Small cell structure, the matte appearance reflects little to no light and is machined with crisp edges and lines in almost any shape.
Low thermal conductivity (normally around 0.033 W/m K) so it is a thermal insulator when you require temperature control.
EVA foam can elongate before breaking with values up to 600%, providing flexibility and resistance to tearing under stress.

How can EVA foam be used?

EVA emulsions are developed into adhesives used in bookbinding, packaging, metal surfaces, bonding plastic films, and coated papers. It is also used with resin and wax additives to create hot-melt adhesives, hot glue sticks, and even children’s foam stickers.

Biomedical drug delivery applications are used to slowly release a compound within the body.

Sports equipment padding such as bicycle saddles, hockey pads, boxing gloves, helmets, fishing rods, and snow or ski boots.

Used for sports shoes to absorb impact shock, such as for sandals or slippers. When compared to natural rubber, EVA is less expensive.

An encapsulation material for crystalline silicon solar cells for photovoltaic modules, a cold-flow improver for diesel fuel, thermoplastic mouth guards, HEPA filter separators, and so much more.

What are the key properties/features of the EVA45 Foam?

Condensation protection
Helps to maintain a seal in high-movement joints
Non-conductive
Lightweight and non-abrasive
Easy to fabricate and non-dusting
Excellent buoyancy
CFC-free, odourless
Impervious to mould, mildew, rot and bacteria
Resistant to water, chemicals, solvents and grease
Plasticizer free
Conforms well to irregular surfaces
Density = 45kg/m3
Sheet size = 2000mm x 1000mm

The EVA75 Foam Sheet is a premium, lightweight closed-cell thermoplastic foam that is competitively used in place of rubber and vinyl products in many electrical applications. What are some of the features?

Non-conductive
Excellent thermal insulation properties
Good UV resistance
Easy to fabricate and non-dusting
CFC-free, odourless
Plasticizer free
Maintains a seal in tight joints
Long-term reliability
Condensation protection
Non-abrasive

What are the main differences between PE foam and EVA foam?

Both are foams, but when using them, you need to take into account the type of polymer:

PE and EVA share similar properties (with polyethylene as the main ingredient) while EVA is a compound that adds vinyl acetate to the polyethylene base; this modification means there is a rubber elasticity in the EVA foam.

The main difference? Resilience. EVA foam returns to its original shape a lot better after compression, and even though it is more expensive, it can be the better option if you need a material to handle frequent compression without losing its form.

What Foam is Best For Your Project?

PE Foam is ideal for applications needing lightweight, durable, and water-resistant materials at a lower cost, such as in packaging and insulation.

EVA Foam is best suited for applications demanding superior shock absorption, high impact resistance, and resilience, such as in sports equipment and footwear.

If you’re needing foam suppliers in Melbourne, Sydney, Brisbane, Perth, Adelaide or anywhere in Australia, MSTOR is your trustworthy supplier for both PE and EVA foam products. We also support you with tape slitting, foam cutting, laminating, and foam cut to size.

Foam Suppliers for Australia Business: Contact MSTOR

Established as a foam, tape and plastic supplier for Australian-wide businesses, MSTOR is a trusted name, supplying and servicing many industries including automotive, insulation, building construction, packaging, medical, and many others.

Whether you need urgent slitting or cutting services, we provide customisation options so you can choose your desired dimensions and specifications that align with your project vision. Our supportive, passionate and knowledgeable staff are always willing to help with any inquiries to provide quality products and services!

From EVA to PE and neoprene for automotive, health care and endless industries, our products adhere to stringent quality standards to offer high-performance materials that meet client expectations.

Place a bulk order online today or reach out for custom orders via sales@mstor.com.au. We also offer free Australia-wide shipping for purchases over $150 to VIC, NSW, QLD, SA and ACT.

Custom sizes and thicknesses available upon request! Please allow 2-5 business days for orders to be fulfilled. Wholesale pricing is also available.

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