If you work in the theatre and film industry, you may be surprised by the prevalence of foam materials and their role in bringing concepts to life.
Expanded polyethylene foams are a staple in the creative industry, used extensively to construct everything from intricate props to large-scale 3D billboards, sculptures, and retail window displays. As such, at Polyformes, we supply both Ethafoam and Plastazote® foam for a range of applications. From the complex bodysuits featured in major films to custom costume elements for television productions, foam materials provide the structural integrity and flexibility required for highly detailed artistic work.
Whether you’re shaping bespoke set pieces, hand-carving detailed puppets, or constructing large-format thematic displays, we combine artistic potential with engineering reliability, and our in-house expertise ensures we provide the right grades, colours, and densities for your vision.
A wide range of foam materials, including Plastazote®, ARPLANK, Ethafoam, Evazote®, Microlen, Stratocell and Supazote®, have several uses within the theatre and film industries.
While some are popular for making on-screen props and costumes, others are essential for constructing sets or protecting multi-million dollar camera, lighting, and audio equipment during transport.
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 theatre and film applications
Plastazote®
Closed-cell, cross-linked polyethylene (PE)
Lightweight; non-toxic; available in vibrant colours; excellent low-temperature heat-moulding (thermoforming) capabilities.
ARPLANK
Isotropic expanded polyethylene (EPE) or expanded polypropylene (EPP)
Isotropic behaviour (uniform multi-directional shock absorption); 100% recyclable; highly resilient.
Ethafoam
Closed-cell, non-cross-linked expanded polyethylene (EPE)
Excellent multi-shock absorption; flexible; easily carved/shaped with basic tools.
Evazote
Closed-cell, cross-linked ethylene vinyl acetate (EVA) copolymer
Tough; elastic and “rubbery” texture; highly resilient to repeated impacts.
Microlen
Closed-cell microcellular foam
Exceptionally fine/uniform cell structure; water-repellent; non-abrasive surface texture.
Stratocell
Laminated closed-cell polyethylene (PE)
Exceptionally high strength-to-weight ratio; highly cost-effective; reusable and structurally stable.
Supazote
Ultra-soft, closed-cell, cross-linked polyethylene (PE)
Premium “soft touch” feel; highly flexible; comfortable against bare skin.
Alongside the foam we supply, we also allow you to source a wide range of exterior packaging, cases and bags.
Our expertise and decades of experience in manufacturing high-performance technical foam components enable us to deliver a broad range of benefits to your art departments, prop makers, and production logistics.
UK manufacture
Short lead times
Entertainment & screen 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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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.
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