ZOTEK® is the best option for a broad range of aerospace, automotive, and/or demanding engineering applications.
ZOTEK® is a family of lightweight, closed-cell, cross-linked technical foams. Manufactured using nitrogen expansion rather than chemical blowing agents, ZOTEK® is pure, exceptionally durable, resilient, and suitable for precision conversion into specialised components. The product line comprises three primary categories. These are ZOTEK® F (a fluoropolymer PVDF foam offering unmatched fire retardancy and chemical resistance), ZOTEK® N (a robust, nylon-based foam designed for high-temperature structural integrity), and ZOTEK® T (a high-performance thermoplastic elastomer foam engineered for flexibility and durability).
At Polyformes, we are a Zotefoams-approved fabricator. We can supply precisely machined ZOTEK® components, including technical packaging, seals, structural inserts, and custom industrial solutions.
ZOTEK® high-performance foams include several variants. These are fluoropolymer (ZOTEK® F and F OSU), nylon-based (ZOTEK® N and NC), and thermoplastic elastomer (ZOTEK® T) foam grades.
ZOTEK® F is a high-performance fluoropolymer PVDF foam offering unmatched fire retardancy, excellent chemical resistance, and superb UV stability.
ZOTEK® NC is a specialised conductive nylon variant designed to protect sensitive components in high-heat environments by combining structural strength with static-dissipative properties.
ZOTEK® F OSU is a specialist aviation-grade foam, specifically engineered to meet the ultra-stringent Ohio State University heat-release standards required for commercial aircraft interiors.
For further details regarding individual material grades, please view the specific pages/datasheets.
Polyformes can split/skive, laminate and butt-weld ZOTEK® 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 ZOTEK® 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.
White
Grey
While specific ZOTEK® grades offer specialist properties, all options provide:
The temperature resistance of ZOTEK foam varies considerably depending on the specific grade. However, ZOTEK® N offers the highest thermal threshold, reliably functioning in environments up to 205°C with minimal shrinkage. ZOTEK® F can also withstand continuous temperatures up to 160°C, far exceeding the thermal limits of standard polyethylene foams.
Both Plastazote and ZOTEK are high-quality closed-cell foams. However, where Plastazote® is a polyethylene (PE) foam used primarily for general packaging, medical devices, and display inserts, ZOTEK® is a high-performance “advanced material” family made from engineering polymers such as PVDF (fluoropolymers), nylon, and TPEs. As such, ZOTEK foams are designed to withstand extreme temperatures, aggressive chemicals, and strict aviation fire codes.
The use of ZOTEK® F is widespread in aerospace because it is inherently fire-retardant. It emits minimal heat, low smoke, and virtually zero toxic gases during combustion. Specialist grades like ZOTEK® F OSU also meet the rigorous Ohio State University (OSU) heat-release standards of the commercial aviation industry while providing significant weight savings that lower long-term fuel costs.
Despite their high-performance polymer bases, ZOTEK® foams are highly versatile and easy to process using conventional conversion methods. They can be precisely die-cut, routed, sawn, split, and waterjet-cut, and they have excellent thermoforming characteristics that allow moulding into highly complex, stable three-dimensional shapes.
ZOTEK® foam is more challenging to convert than standard polyethylene foams. ZOTEK® materials require higher, specialist processing temperatures due to the greater thermal stability and elevated melting points of their base polymers. However, fabricators can securely bond it to a range of substrates, including engineering plastics, metals, composite materials, and itself.
ZOTEK® is ultra-lightweight, extremely low-emission, inherently pure, and completely waterproof. The material withstands rigorous chemical washdowns and sterilisation cycles, demonstrating resistance to aggressive hydrocarbons, aviation fuels, hydraulic fluids, and concentrated acids. It also exhibits exceptional weatherability and ultraviolet stability, whilst also remaining tough and highly resilient under repeated high-energy impacts.
ZOTEK® foam is particularly popular for several highly demanding industrial and technical applications. This includes aerospace cabin insulation, aircraft seating components, and environmental sealing. It is also used for automotive engine insulation, high-temperature gaskets, and lightweight structural cores. In defence and high-tech sectors, it is utilised for handling sensitive electronics, radar-transparent components, and severe-service vibration isolation. Additionally, its high purity and extreme temperature endurance make it suited to cleanroom environments, semiconductor manufacturing equipment, and specialised biotech processing components.
Polyformes is one of the longest-established foam suppliers and converters in the UK, having been supplying innovative, commercially successful foam solutions for well over 40 years.
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