If you need the highest-performance cushioning, insulation, or dampening for your application, Zotefoams’ materials are the market-leading option.
Zotefoams PLC is a UK-based manufacturer of closed-cell, cross-linked foams. Its popular Plastazote® foam is the industry standard for high-performance foam inserts, returnable packaging dunnage and a range of similar applications. Its specialist foams, including Evazote® and ZOTEK®, are also widely used in orthotics, medical, aviation, buoyancy and sports applications. Its unique manufacturing process produces foams that are incredibly pure, non-toxic, consistent and suitable for direct skin contact.
At Polyformes, we are proud to be among the UK’s first Zotefoams-approved fabricator. Our close working relationship, material expertise, in-house design team and extensive conversion equipment allow us to supply the full range of Zotefoams materials, alongside a huge array of converted products and packaging.
You can source the following Zotefoams materials from Polyformes, in sheet form or as pre-fabricated products.
The main difference between Zotefoams and other technical foams lies in the manufacturing process. Zotefoams’ unique three-stage nitrogen-expansion process eliminates toxic chemical residues, heavy volatile organic compounds (VOCs), and odours, resulting in a significantly purer, lighter, and more structurally uniform closed-cell foam.
Zotefoams are widely recognised as a gold standard for highly regulated industries because they are inherently pure, non-toxic, hypoallergenic, and latex-free. Because no chemical blowing agents are used in production, there is no chemical out-gassing or toxic migration. These properties make specific ranges, like Plastazote®, exceptionally safe for direct food contact, medical packaging, and healthcare applications, such as diabetic orthotic insoles.
The aerospace sector heavily relies on Zotefoams, particularly their advanced ZOTEK® fluoropolymer (PVDF) range, because the materials offer an unmatched strength-to-weight ratio with zero off-gassing. In enclosed aircraft environments, the foam’s strict compliance with aviation fire, smoke, and toxicity (FST) standards, combined with its high thermal insulation and resistance to aviation fluids, makes it vital for lightweight cabin insulation and seat manufacturing.
While both are closed-cell polyolefin foams manufactured by Zotefoams, they use different base polymers to target different physical requirements. Plastazote® is a polyethylene (PE) foam known for its rigidity, exceptional purity, and superb chemical inertness, making it ideal for medical devices, museum conservation, and protective packaging. Evazote® is an ethylene-vinyl acetate (EVA) copolymer foam engineered to be more flexible, making it the preferred choice for impact-heavy sports equipment, footwear, and automotive parts.
Headquartered in Croydon, London, Zotefoams plc is a British manufacturing company specialising in the design and production of high-performance, closed-cell, cross-linked polymer foams.
The company uses a unique manufacturing process. Unlike traditional foam manufacturers that rely on chemical blowing agents, which often leave toxic chemical residues and high levels of VOCs (volatile organic compounds), Zotefoams utilises a proprietary three-stage nitrogen expansion process. This technique saturates polymers with pure nitrogen gas at high temperature and under intense pressure, resulting in an incredibly pure, lightweight material with a highly consistent cell structure.
Zotefoams’ manufacturing technique also means that their foams do not “out-gas” (i.e. release fumes after manufacture). As a result, they are the industry standard across many highly regulated sectors, including medical packaging, orthotics (such as diabetic insoles), aerospace insulation, and automotive component design.
The company offers several foam materials/brands, most notably Plastazote® and Evazote® (cross-linked polyolefins), alongside its advanced ZOTEK® range.
Polyformes is a Zotefoams-approved fabricator in the UK, allowing us to supply your business with the full range of materials and/or fabricated foam products.
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