AZOTE® foams from Zotefoams is the most popular option if your business needs a premium, high-performance foam material, insert or product.
AZOTE® foams are a collection of closed-cell, cross-linked polyolefin foams, which include Plastazote®, Evazote®, and Supazote®. Their major benefit is the use of a physical nitrogen-expansion process rather than using chemical blowing agents. This gives them unique purity, consistency, structural integrity, and crucially, makes them odourless, non-toxic, and hypoallergenic. They also provide exceptional isotropic cushioning protection, providing the same performance in all directions (X, Y, and Z).
At Polyformes, we are proud to be among the first UK Zotefoam-approved fabricators. Our close working relationship with Zotefoams, extensive material expertise, and state-of-the-art foam conversion equipment allow us to supply AZOTE® foams as material buns or as pre-fabricated products and packaging.
There are three material options in the AZOTE® foam range, each offering several benefits and suitability for specific industries/requirements.
All AZOTE® foam materials provide the following benefits:
AZOTE® is the umbrella brand name for an entire family of polyolefin closed-cell foams manufactured by Zotefoams. Plastazote® is one of the specific materials within the AZOTE® family. While the AZOTE® product line also includes flexible, rubber-like options (Evazote®) and ultra-soft options (Supazote®), Plastazote® specifically refers to the rigid, lightweight, closed-cell, cross-linked polyethylene (PE) grades widely used for high-performance packaging, orthotics, and archival storage.
AZOTE® foam is non-toxic – and generally exceptionally safe – because it is expanded using a nitrogen gas autoclave process rather than chemical blowing agents. Standard chemically-blown foams leave behind toxic, volatile organic compounds (VOCs) and chemical residues that cause unpleasant odours and skin irritation. Because nitrogen is completely inert, AZOTE® foams are pure, non-toxic, hypoallergenic, and entirely odorless, making them safe for direct skin contact and medical environments.
AZOTE® foams are highly thermoplastic and easy to heat-mould. When exposed to temperatures between 85°C and 140°C, the polyolefin foam material softens without losing its structural cell integrity. Converters can then use various moulding techniques to match intricate, bespoke contours. This property is why Plastazote® is the leading foam used by podiatrists to mould custom orthopedic insoles directly to a patient’s foot.
AZOTE® foam is highly resilient against wind and water, but its resistance to ultraviolet (UV) sunlight depends heavily on its colour. Standard white and brightly coloured AZOTE® foams may experience surface yellowing, powdering, or become brittle if left in direct sunlight for prolonged periods (up to 1 – 2 years). However, black AZOTE® foam grades have superior UV resistance due to the protective nature of the carbon black pigments used, allowing them to withstand years of harsh outdoor exposure without losing mechanical strength.
Polyformes is an official Zotefoam-approved fabricator, reflecting our deep understanding of the AZOTE® materials and our high-quality foam conversion service.
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