If you need a high-quality foam for protection, medical, packaging, or even presentation applications, Plastazote® is the industry-standard choice.
Plastazote® is a lightweight, closed-cell, cross-linked polyethylene foam. Manufactured by Zotefoams, Plastazote® foam is durable, versatile and easy to convert into a range of products. It is available in a wide variety of grades defined by density, rigidity, and special functional properties. It provides a high strength-to-weight ratio and excellent recovery characteristics after compression, whilst its use of nitrogen rather than chemical blowing agents during manufacture makes it non-toxic, odourless and suitable for a huge range of applications.
At Polyformes, we are official Plastazote® foam suppliers and converters. We can supply Plastazote® sheets – in the exact size and thickness you require – or converted products, including foam packaging, case inserts, promotional products, and more.
Plastazote® foam material is typically either Low Density (LD) or High Density (HD), ranging from 15kg/m³ to 115kg/m³.
Flame-retardant, conductive and static-dissipative grades are also available. Suffixed FR and FM, the flame-retardant Plastazote® meets various standards, including BS, DIN, EASA, ISO, FAA, FAR, FAA.JAR and FMVSS specifications. Flame-retardant materials are commonplace in the automotive, aerospace, and construction industries.
Conductive grades, suffixed CN, and static dissipative grades, suffixed SD, combine all the general properties of the specific grade with reduced volume resistivity. They are suitable for a wide variety of applications, including the storage, protection, and transport of electronic components and devices, as well as EMC shielding.
Low-density (LD) Plastazote® grades are generally softer and used for cushioning, packaging, and medical applications.
High-density (HD) Plastazote® grades are firmer and more rigid, designed for applications that require greater support, such as heavy-duty protection.
Metallocene-catalysed polyethylene (MP) Plastazote® foam refers to specific grades produced using metallocene catalyst technology. These grades typically offer higher purity and performance.
For further details regarding individual material grades, please view the specific pages/datasheets.
Polyformes can split/skive, laminate and butt-weld Plastazote® material to the specific dimensions you require. You can also select skin or cell finishes. MOQs may apply to certain size/material options.
Please get in touch with a member of our team to discuss your requirements.
The majority of Plastazote® grades are suitable for conversion using the following processes:
Please note that not all colours are available in all grades. Please view the individual material pages for full availability.
Due to individual display settings, the colours you see on your screen may vary slightly from the actual material colour.
Black
Dark Grey
Grey
Silver
Pale Grey
White
Navy
Blue
Teal
Violet
Mauve
Cream
Healthcare
Pink
Red
Orange
Yellow
Gold
Jaguar
Green
Jade
Spring
Lime
Olive
Plastazote® foam offers several beneficial properties, including:

Plastazote® is a high-performance foam material produced by Zotefoams. Plastazote® is manufactured by expanding heated low-density polyethylene (LDPE) with nitrogen. By combining this with a high-energy radiation process, the result is a cross-linked, closed-cell foam. MP grades use a metallocene-catalysed polyolefin for increased toughness and improved heat moulding properties.
Plastazote® is recyclable at the end of its usable life, although specialist recycling facilities are required to process it. However, due to the material’s durability, it also reduces environmental harm through prolonged reuse (it is not typically specified for single-use applications).
Plastazote® is a closed-cell foam. This terminology means that the cells are not interlinked. As a result, Plastazote® has excellent compression set performance (i.e. it returns to its original shape after compression or impact) and does not absorb water.
The specific grade of Plastazote® material determines the applications it is suitable for. However, in general, Plastazote® is suitable for packaging, medical and orthopaedics, sports and leisure products, prop making, automotive and aviation components, and more.

Plastazote® foam, a member of the Azote family, can be easily shaped and cut. Converters can bond it to other materials (fabrics, itself, wood, metal, etc.). Converters can also mould it at relatively low temperatures, as polyethylene has a low softening temperature.
Plastazote® is lightweight, non-toxic, odourless, water-resistant, and buoyant. Users can wash, disinfect, and wipe the material clean, and it also has excellent chemical resistance to most oils, solvents, acids, and alkalis. It is weatherproof, has good ultraviolet stability, is durable, tough and flexible and recovers repeatedly from impacts. It is highly energy-absorbent and a very good thermal insulator.
Plastazote® foam is suitable for a wide range of applications, including floats and buoyancy aids, surfboards, pool toys, sleeping mats, and gym and exercise mats. It is popular for body protection in various sports, as well as for shoe insoles and helmet liners. It has important uses in health care, including supports, orthopaedic shoes, surgical splints and collars, and mobility equipment for people with disabilities. Theatres and film sets around the world use it to create stage props, set designs, costumes, masks, and hats. Other applications include sound and pipe insulation, gaskets, anti-vibration pads, buoys, fenders, oil booms, and case inserts.
With extensive stockholding, in-house conversion facilities, expert designers, and a close working relationship with Zotefoams (manufacturers of Plastazote®), we can offer your business numerous benefits.
Official suppliers
Trade service
Material knowledge
In-house processing
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Disclaimer: Generative Ai may be used on this site when specifically creating content and information relating to the products, processes and materials we use at Polyformes. Any Ai content undergoes stringent reviews and editing by humans to check accuracy. Please view this content policy for further details.
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If you need high-performance, single-trip packaging to ship your valuable or fragile products, custom foam end caps are the most cost-effective option. 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 packaging experts:
Technical Sales
Emma Atterbury
[email protected] | 01525 852 444
Quotes / Pricing
Amy Donnelly
[email protected] | 01525 852 444
Customer Service
Ian Rumsey
[email protected] | 01525 852 444




