Zotefoams

Plastazote®

Zotefoams

Plastazote®

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.

No obligation
UK experts
Competitive pricing
Material grades

Plastazote® material options

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.

High-density grades (HD)

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)

Metallocene-catalysed polyethylene (MP) Plastazote® foam refers to specific grades produced using metallocene catalyst technology. These grades typically offer higher purity and performance.

Specifications

Technical information and options

For further details regarding individual material grades, please view the specific pages/datasheets.

Plastazote® foam sheet sizes

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.

Conversion

The majority of Plastazote® grades are suitable for conversion using the following processes:

Available colours

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

Advantages

Plastazote® foam properties

Plastazote® foam offers several beneficial properties, including:

Non-toxic, odourless, and resistant to most acids, alkalis, and solvents.
Uniform density and cell size for consistent performance.
High structural integrity with minimal mass, reducing shipping costs.
Safe for direct skin contact and archiving (no chemical blowing agents).
Excellent energy absorption, recovering quickly from repeated impacts.
Buoyant with virtually zero water absorption due to closed-cell structure.
Easily thermoformed, routed, die-cut, and waterjet cut.
A service engineer taking a tool out of Plastazote case inserts on site
Plastazote® experts

FAQs

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.

A person looking at a Plastazote product in a shop
More info

Additional information

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.

UK foam suppliers

Why work with us?

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
Polyformes is an official UK supplier of the full range of Zotefoam materials, alongside a wide range of alternatives.
Trade service
We can supply foam converters, packaging companies and component manufacturers with material or finished products.
Material knowledge
Our in-house team of foam experts, designers and support staff has extensive knowledge of all Plastazote® grades and options.
In-house processing
We are one of the UK’s leading Plastazote® foam converters, with extensive in-house CNC, die-cutting, waterjet, and thermoforming equipment.
Short lead times
We can supply your Plastazote® sheets, packaging, or products on exceptionally short lead times thanks to our extensive stockholding.
UK experts
If you’re not exactly sure which foam is best for your requirements, our team is on hand to provide free, expert advice.
Wide range of options

Similar foam materials

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UK experts

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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