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What is Foam Used For?

Foam, particularly EPE (expanded polyethylene) foam, due to its resilience to impact and high pressure, its water-proofing qualities, and its ability to be formed into intricate shapes, has a large variety of applications in all types of industries and sectors. These industries and sectors include:


Construction is one of the larger industries, regularly using foam for various applications, both due to its practical use, and its cost-effectiveness when compared to other traditional materials. Foam’s uses in construction include:

  • Joint filling
  • Expansion pads
  • Water-proofing
  • Insulation
  • Crane sand replacement materials

Aerospace and Aircraft

The aerospace and aircraft industry relies on materials that are simultaneously flexible, durable and extremely lightweight. Foam (especially EPE) covers all these criteria and more, and is therefore used in the manufacture of various aerospace and aircraft parts, including:

  • Seating
  • Gaskets
  • Noise reduction applications
  • Flight case inserts


The automotive industry is another industry that relies on lightweight, vibration-resistant, and durable materials, such as foam in the manufacturing of vehicles and replacement parts. Another reason foam (particularly EPE foam) is routinely used in the automotive industry, is down to its oil and water resistance, particularly in parts such as:

  • Manifold gaskets
  • Washers and spacers
  • Tubing and sleeves
  • Toolbox inserts

Cosmetics and Beauty

The cosmetics and beauty industry uses foam because it’s non-toxic, can be manufactured to various grades of softness, and has the ability to be recycled and reused. Applications include:

  • Applicator sponges
  • Twist-Flex hair curlers
  • Toe and Finger separators, for manicures and pedicures
  • Latex-Free sponges


Foam has a wide range of properties suited to the packaging industry, including:

  • Vibration resistance
  • Oil and Chemical resistance
  • Water resistance
  • Flexibility
  • Durability
  • Mouldability

All of these properties combined, make foam the perfect material for all types of packaging inserts, including those required to protect valuable and fragile electrical components or delicate ornaments etc.

Promotional and Retail

From corporate displays to shop displays, to sporting event paraphernalia and souvenirs, foam is used throughout the promotional and retail industry, due to it being hardwearing, yet soft and flexible, and able to be brightly coloured according to team colours and branding.


The electronics industry not only requires unique packaging solutions, designed to protect complex components, it also requires a packaging solution that can lessen the chances of damage to circuitry within components, due to electrostatic charge, caused by the constant contact of the materials used for packaging.

The reason why foam is routinely used in the electronics industry is that it has the potential to be made less conductive, therefore significantly reducing the risk of electrostatic charge occurring, particularly during transportation.

Sports and Leisure

Whether it is for floatation devices, protective suits, trainers or gym accessories, such as mats, or padding for exercise equipment, knee protectors, shin pads or chest protectors etc., the sports and leisure industry would be lost without foams. The reason for foam's wide use throughout the sport and leisure industry is largely due to its impact resistance, flexibility, and hardwearing properties.