If you are involved in designing or manufacturing for the aerospace industry in the UK, you know there is very little margin for error with your aerospace packaging and foam products.
At Polyformes, our expertise covers the full spectrum of aerospace applications. We specialise in high-performance Plastazote and ZOTEK closed-cell foam, including flame-retardant grades that meet FAR/CS 25.853(a) App F Pt. 1 requirements. These materials provide exceptional weight reduction, durability, and comfort for seating and soft trim. At the same time, our broader range – including LD45, HD115, and HD110 – enables precise, custom-engineered solutions such as rotor blade spacers and routed components.
By taking advantage of our in-house capabilities, including thermoforming, routing, waterjet cutting, and profiling, our designers can help you source the optimal foam material, part, product or packaging for your application.
Technical, closed-cell polyolefin or fluoropolymer foams find extensive use within the aerospace industry.
They are predominantly used in two main areas, firstly for aircraft interior components and parts, and secondly for tool control (FOD prevention) and protective packaging for high-value aviation components.
Please note that this list is not exhaustive. If you cannot see your specific application listed, please contact us to see how we can assist.
Foam
Material type
Key benefits and properties
Primary aerospace applications
Plastazote®
Closed-cell, cross-linked polyethylene (PE)
Ultra-lightweight;, extremely pure (nitrogen-blown); high chemical/oil resistance, low compression set; and available in flame-retardant (FR) and conductive grades.
ARPLANK
Isotropic expanded polyethylene (EPE) or expanded polypropylene (EPP)
100% recyclable; isotropic behaviour (equal shock absorption on all 3 axes); non-abrasive surface; wide temperature range (-60°C to 100°C); chemical inertness.
Ethafoam
Closed-cell, non-cross-linked expanded polyethylene (EPE)
Superb multiple-impact protection; high load-bearing capacity; excellent moisture and chemical resistance; available in anti-static (ESD) and FR grades.
Evazote
Closed-cell, cross-linked ethylene vinyl acetate (EVA) copolymer
Tougher and more resilient than Plastazote; exceptional impact recovery; high buoyancy; superior resistance to UV/weathering.
Microlen
Closed-cell microcellular foam
Fine-celled, highly aesthetic finish; smooth texture; good thermal insulation; lightweight; easily thermoformed.
Stratocell
Laminated closed-cell polyethylene (PE)
Cost-effective; high-yield cushioning performance; multi-layer structural rigidity; lightweight; excellent moisture resistance.
Supazote
Ultra-soft, closed-cell, cross-linked polyethylene (PE)
Softest and most flexible foam in the Azote range; highly elastomeric; comfortable touch; excellent energy-absorbing properties.
ZOTEK
High-performance closed-cell fluoropolymer (ZOTEK F) or nylon (ZOTEK N) foams
Exceptional Fire, Smoke, and Toxicity (FST) performance; heat resistant up to 160°C; highly biological/chemical inert; ultra-lightweight.
Alongside the foam we supply, we also allow you to source a wide range of exterior packaging, cases and bags.
Our expertise and experience in manufacturing high-performance aerospace foam components and protective transit packaging, along with our status as an approved Zotefoams fabricator using premium materials like Plastazote® and ZOTEK®, enable us to deliver a broad range of benefits to your supply chain, assembly lines, and MRO (Maintenance, Repair, and Overhaul) operations.
UK manufacture
Short lead times
Aerospace foam experts
Single source supply
Vast industry experience
Sustainability
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If you need high-performance foam inserts, packaging, products or materials, we can help. Please contact a member of our team for a free consultation and quote.
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Our experts
The information on this page was written and checked by our team of experts. You can contact them to discuss your requirements, or for any questions you may have, using the details here.
Sales Enquiries
[email protected]
01525 852 444 (option 1)
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01525 852 444 (option 2)
