Polyformes is proud to now be an Approved Fabricator as part of Zotefoams Approved Partner Programme
Market knowledge

Medical Foam

Market knowledge

Medical Foam

Working in the medical, healthcare, or mobility sectors, you’ll understand that high-performance foam solutions that meet the most stringent safety standards can be essential.

At Polyformes, we specialise in the supply, manufacture, and conversion of high-quality Evazote® and Plastazote® foams, both of which are assessed in accordance with ISO 10993 to ensure they are safe for clinical use. These materials are favoured for their chemical resistance and unique ability to be virtually transparent in MRI, CT, and X-ray scans. Their durability, water resistance, and soft-touch comfort also make them ideal for a wide range of applications, including orthopaedic splints, collars, braces, hip protector pads, and prosthetic limbs. In addition, these foams are the industry standard for medical footwear, wheelchair padding, and ergonomic sanitary seating. We also provide protective packaging for fragile medical instruments and manufacture a diverse range of hydrotherapy aids, such as aqua-joggers and dumbbells, which physiotherapists use to support patients recovering from spinal, pelvic, and joint injuries.

So, whether you require custom-moulded supports and flotation devices or raw foam sheets and blocks for your own in-house fabrication, our team of experts delivers the quality and consistency you need.

No obligation
UK experts
Competitive pricing
Applications

Medical foam uses

Several foam materials, including Plastazote®, Evazote® and Supazote®, are specifically and actively used within the medical and healthcare industry.

Some additional options (ARPLANK, Stratocell, and Microlen) are occasionally used in general, non-sterile shipping or protective outer transport boxes for medical equipment, but they are primarily industrial-grade packaging and construction materials rather than dedicated medical foams.

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 medical foam applications

Plastazote®

Closed-cell, cross-linked polyethylene (PE)

Latex-free, non-toxic, and hypoallergenic; pure and non-staining (nitrogen-blown); radiolucent (X-ray, CT, and MRI clear); can be thermoformed directly onto the skin.

Orthotic shoe insoles and diabetic footwear
Cervical collars and neck braces
Splints and custom body-moulded casts
Surgical positioning pads
Prosthetic limb linings

Ethafoam

Closed-cell, non-cross-linked expanded polyethylene (EPE)

Outstanding shock absorption and structural rigidity; low abrasion surface protection; 100% recyclable; resistant to mildew/bacteria; high load-bearing capacity.

Protective internal transit inserts for heavy medical devices
Shock-resistant packaging for fragile laboratory test equipment
Custom casing for delicate surgical kits

Evazote

Closed-cell, cross-linked ethylene vinyl acetate (EVA) copolymer

Softer, more resilient tactile feel than Plastazote; high impact resistance and energy dispersion; chemically inert and highly durable; water-resistant and easy to sanitise.

Wheelchair and mobility scooter padding
Soft-touch sanitary medical seating
Hip protector pads
Hydrotherapy and aqua-aerobics equipment
Diagnostic device components

Supazote

Ultra-soft, closed-cell, cross-linked polyethylene (PE)

Extremely soft and high-comfort tactile feel, excellent chemical resistance to oils/acids, non-toxic and completely odourless, high durability under repeated compression.

Skin-contact padding for medical dressings
Pressure-relief cushions
Comfort linings for medical appliances
Delicate cosmetic/medical device packaging

ZOTEK

High-performance closed-cell fluoropolymer (ZOTEK F) or nylon (ZOTEK N) foams

High-performance (PVDF, Nylon, or TPE-based); drastic temperature and chemical resistance; biocompatible (complies with ISO 10993); closed-cell structure avoids biological fluid absorption.

Cleanroom equipment packaging and trays
High-purity pharmaceutical manufacturing seals
Premium medical insoles requiring long-term energy return
Surgical support systems
Packaging

Additional products

Alongside the foam we supply, we also allow you to source a wide range of exterior packaging, cases and bags.

UK foam converters

Why work with us?

Our expertise and experience in manufacturing high-performance medical foam components and protective transit packaging, along with our status as an approved Zotefoams fabricator, enable us to deliver a broad range of benefits to your medical supply chain, clinical environments, and production lines.

UK manufacture
Manufacturing your medical foam parts and device packaging at our cutting-edge UK foam conversion facility guarantees the highest quality, strict adherence to stringent medical tolerances, and reliable performance in critical healthcare applications.
Short lead times
Our process, from initial consulting and CAD design through to rapid prototyping, sample testing, and full-scale manufacture, is quick, efficient, and built to keep pace with the fast-moving demands of the medical and pharmaceutical sectors.
Medical foam experts
Our team can advise on the exact foam densities and biocompatibility specifications required for your specific application. This includes medical-grade, non-toxic, and hypoallergenic foams suitable for direct skin contact, component positioning, orthopedic devices, or cleanroom-compatible packaging.
Single source supply
We can manufacture both your precision medical device foam components and your protective transit packaging inserts. As part of Macfarlane Packaging, we can also offer a much broader range of sundries and stock lines too.
Vast industry experience
We have more than 4 decades of experience converting technical foams into high-performance protective packaging, material-handling inserts, and engineered parts for medical device OEMs, healthcare providers, and pharmaceutical suppliers.
Sustainability
As well as reducing material use, pack weights and production waste, we help you meet strict environmental and corporate social responsibility targets by offering a range of lightweight, durable, and recycled materials.
Wide range of options

Similar foam products

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