Do you handle electronics at home or in your workplace? Whether it's smartphones, tablets, laptops, or sensitive industrial equipment, it’s important to keep them protected during transportation and storage.

By using thin foam sheets, manufacturers, retailers, and consumers can benefit from their shock absorption, moisture resistance, and anti-static properties.

This blog will explore the benefits of using thin foam sheets for protecting fragile electronics, covering their characteristics, customisation options, anti-static properties, and primary applications. 

Thin Foam Sheets: What Are They?

Polyethylene is one of the most used foam materials on the market, but it isn’t given its just due for its usefulness on endless projects. 

Formed by the heating of polymer compounds, polyethylene foam can handle additives to its formula to alter its properties before it is heated and extruded into the solid-state form. 

Although polystyrene is a popular option for insulation, polyethylene can work with packaging, flotation devices, shock absorbers, masonry supplies, and so much more. Polyethylene always returns to its original form after compression, providing security and cushion where necessary. 

What Are The Characteristics of Thin Foam Sheets?

What are some of the characteristics of thin  foam  sheets? 

1. Polyethylene (PE) and Expanded Polyethylene (EPE)

Thin foam sheets are commonly made from two materials:

Polyethylene (PE) Foam:

• Features a closed-cell structure that offers excellent insulation and impact resistance.

• The smooth surface makes it ideal for wrapping fragile components.

• It offers lightweight protection without making packaging heavy.

• It is resistant to moisture and chemical exposure.

Expanded Polyethylene (EPE) Foam:

• It is a lot more flexible and resilient than standard PE foam.

• Provides excellent shock absorption and cushioning.

• It is resistant to water, chemicals, and UV rays.

• It is more sustainable for eco-conscious businesses.

PE and EPE ensure that fragile electronics are protected against external shocks and the environment, from heavy rain to extreme heat.

2. Shock Absorbant 

Thin foam sheets absorb shocks and impacts, so you don’t need to stress if an item is accidentally knocked or dropped during transit. Due to their closed-cell structure, these sheets dissipate energy, preventing sudden shocks from damaging electronic components with fragile wiring. 

Put simply, foam sheets act as a buffer between fragile electronics and external pressure, so delicate parts such as screens, motherboards, and processors stay intact. Without shock absorption materials, businesses could be paying a lot more money on replacements or repair work.

3. Lightweight

Since they don’t make packaging heavy (and are non-abrasive), thin foam sheets are perfect for shipping and transportation. The lighter packaging also allows businesses to save on shipping costs.

For example, companies shipping large volumes of electronics benefit from foam sheets, which provide a cost-effective and sustainable packaging solution. MSTOR’s  PE45 Foam Sheet  is only 45kg/m3 in density and 2000m x 1000mm sheet size.

PE45 Foam Sheet

Key features/properties:

• Excellent thermal insulation

• Lightweight and non-abrasive

• UV resistant

• Easy to fabricate and non-dusting

• Excellent buoyancy

• CFC-free, odourless

• Impervious to mildew, mould, rot  and bacteria

• Resistant to water, chemicals, solvents and grease

• Excellent vibrations dampening

• Non-conductive

EVA75 Foam Sheet

Some of the key properties/features include:

• Long term reliability

• Condensation protection

• Maintains a seal in high-movement joints

• Non-conductive

• Easy to fabricate

• Excellent thermal insulation

• Lightweight and non-abrasive

• Excellent buoyancy

• CFC-free, odourless

• Impervious to rot, mould and mildew

• Resistance to chemicals, water, solvents and grease

• Conforms to irregular surfaces

• Plasticiser FREE

Customisation Options

Electronics come in various shapes and sizes, and so do thin foam sheets, so there are many ways to customise. Let’s explore some of the ways you may be able to use these products:

1. Custom Thickness for Different Electronics

Thin foam sheets are available in various thicknesses to cater to different protection needs:

• Ultra-thin sheets (1-3mm) are best for wrapping delicate screens or lightweight devices like smartphones and tablets.

• Medium-thickness sheets (4-10mm) work for laptops, cameras, and gaming consoles.

• Thicker sheets (11mm+) are ideal for bulkier, expensive electronics that need a bit more cushioning.

Whether you’re looking for sheet or plank from polyethylene, it has a rigidity that holds its shape in place when cut into thick sections. Although strong, it can be easily cut to create form-fit inserts or laminated together to create thicker sections for furniture inserts or specialised packaging.

Likewise, rolls of polyethylene are thin sheets perfect for insulation, wrapping around pipes for insulation, sealing between foundations, and sill plates in buildings, or creating bags to protect goods while cutting back weight and space.

Even polyethylene’s molecular compounds can be customised with both physically-cross-linked and chemically-cross-linked polyethylene. This is because it’s easier to break and re-form a physically cross-linked material. The range of densities, formulations, and styles are substantial on their own and have multiple uses for each variation. 

Red PE Foam Sheet

The RED PE Foam Sheet is a quality closed-cell foam made from polyethylene and blended copolymers. The closed structure is also resistant to water, chemicals, solvents, grease, mildew, rot, mould and bacteria. Applications include arts & crafts and product packaging.

At MSTOR, custom sizes and thicknesses are available upon request. 

2. Density Variations for Protection

Depending on the level of protection required, foam sheets come in different densities:

• Low-density foam: Provides soft cushioning for lightweight items.

• Medium-density foam: Offers moderate protection, balancing flexibility and support.

• High-density foam: Provides the firmest support, preventing movement and absorbing significant impacts.

The higher the density of the polyethylene, the smaller or thicker the cell walls are, creating a stronger material. 

PE120 Foam Sheet

For example, PE120 Foam (2000mm x 1000mm) is a premium quality closed cell foam made from polyethylene. 

It has a high level of consistent chemical cross linking, which results in smooth fine-cell structure suitable for isolation joint applications in the construction industry, sports equipment, carpet underlays, safety packaging and gasket applications in the automotive field. 

How Can You Use Thin Foam Sheets?

From flexibility to protective properties, foam sheets have many uses.

Packaging and Shipping Electronics

Polyethylene foam can be moulded to fit the shape and size of a product, supporting packaging by:

• Wrapping around devices to provide a protective layer.

• Acting as a cushioning layer within boxes to stop any movement.

• Reducing the chances of damage from vibrations and impact.

Protection Against Moisture and Corrosion

Moisture exposure can lead to corrosion and internal damage in electronics, but polyethylene sheets help by:

• Creating a protective barrier against humidity and water vapour.

• Preventing oxidation in metal components.

• Keeping devices safe in all environmental conditions.

Let’s take a look at the EVA230 Foam Sheet:

EVA foam may be found in all types of appliances, including automotive, building, marine, electronics, healthcare, packaging, sports, leisure, and recreation. EVA is competitively used in place of rubber and vinyl products in many electrical applications. 

Buffering Against Physical Stress

Electronics can experience different types of stress during handling and transit, and foam sheets help by:

• Absorbing pressure from stacking and rough handling.

• Stopping scratches and dents from direct contact with hard surfaces.

• Keep packaging stable to avoid accidental shifts.
  

Blue IXPE Foam Sheet

The Blue IXPE Foam Sheet (2000mm x 1200mm) is lightweight, flexible, and soft to the touch, yet very strong and tough. 

It has low water absorption, good resilience to moisture, good chemical resistance, good UV properties, heat insulation, and resistance to aging and high temperatures. It also dies-cuts and slits easily for custom sizing!

Anti-Static Fire Retardant PE Foam Sheet

This foam is specially made to be anti-static fire resistant with a closed cell cross-linked polyethylene structure that is tough and flexible.

It has great tear strength, low water absorption, chemical resistance, great UV properties, and is free of heavy metals such as plasticisers and CFCs. It is dust-free when cut, easy to fabricate, and is AS1530.3 fire-rated compliant.

Looking for Foam Suppliers in Australia? Reach To MSTOR

MSTOR has established a wide range of high-quality materials and products, including foam, tape and plastic. We have been supplying and servicing many industries, including automotive, insulation, building, construction, packaging, medical, and many others.

Every project is unique, and we offer a range of  services,  such as  tape slitting,  foam cutting,  and   laminating. These customisable options help you choose the right dimensions and specifications that align with your vision. 

With years of experience and a strong focus on customer satisfaction, customisable options for all products and wholesale pricing, MSTOR has products available Australia-wide!

Do you need thick foam sheets? Fill out our online enquiry form today or  contact  us at  sales@mstor.com.au with custom orders or any other enquiries. As  foam suppliers for Melbourne,  Sydney,  Brisbane,  Perth,  or  Adelaide  businesses and residents across Australia, we’re always willing to help. Bulk order online now!

We offer FREE shipping on purchases over $150 to VIC, NSW, QLD, SA, and ACT. For custom orders, please allow 2-5 business days for them to be fulfilled.