Cross-linked Polyethylene Foam (XLPE Foam)

Cross Linked Polyethylene Foam XLPE Foam for Packaging, Insulation and Custom Foam Parts

Topsun cross linked polyethylene foam, also called XLPE foam or crosslinked PE foam, is a lightweight closed-cell foam material designed for cushioning, shock absorption, thermal insulation, acoustic insulation, moisture protection and custom foam fabrication. It offers a fine cell structure, smooth surface, good elasticity and stable long-term performance for industrial, automotive, construction, packaging, sports and medical applications.

XLPE foam can be supplied in sheets, rolls, blocks, tapes, inserts, gaskets and precision die-cut foam parts. Topsun can customize density, thickness, size, color, adhesive backing, lamination and processing method according to your application, drawing or sample.

Key Features of Cross Linked Polyethylene Foam

• Lightweight, soft and elastic, suitable for cushioning and protective foam applications.

• Excellent buffering, shock absorption and impact resistance performance.

• Closed-cell structure with low water absorption and excellent moisture-proof performance.

• Good sound insulation and thermal insulation performance for construction, HVAC and transport applications.

• Good chemical stability with resistance to acids, alkalis and corrosion.

• Non-toxic, odorless, environmentally friendly and recyclable material option.

• Easy to cut, die cut, laminate, engrave, mold and process for customized foam parts.

Crosslinked Polyethylene Foam Technical Specification

What Is PE Foam and XLPE Foam?

PE foam, or polyethylene foam, is a lightweight closed-cell foam material made from polyethylene. Cross linked polyethylene foam, commonly called XLPE foam, has a more stable foam structure, fine cell appearance, better resilience and stronger durability than many standard non-crosslinked PE foam materials.

XLPE foam is soft to the touch, elastic, low in water absorption and chemically stable. It provides cushioning, protection, insulation, vibration damping, sound reduction and moisture resistance. It can also be processed by cutting, die cutting, lamination, adhesive backing and molding for custom industrial products.

Topsun PE Foam Process Flow

Topsun supports PE foam and XLPE foam production and converting for different industries. According to the required density, thickness, hardness and final application, the foam can be processed into sheets, rolls, blocks, tapes, gaskets, protective inserts, insulation parts and molded foam components.

For OEM projects, customers can provide drawings, samples, CAD files or application requirements. Topsun will help recommend suitable foam density, processing method, adhesive backing and packaging format.

Benefits of XLPE Foam

Wide range of densities: XLPE foam is available in multiple density options, allowing manufacturers to select the ideal balance of cushioning, strength and performance for specific applications.

Superior thermal insulation: Its closed-cell structure provides excellent thermal resistance, making it suitable for pipe insulation, HVAC insulation and temperature-sensitive packaging.

Excellent water resistance: XLPE foam absorbs very little moisture and helps maintain performance in humid or wet conditions.

Chemical resistance: The material offers resistance to many chemicals, oils and solvents, making it suitable for industrial and commercial use.

Cushioning and flexibility: XLPE foam provides shock absorption, impact protection and flexibility for protective packaging and cushioning applications.

High strength-to-weight ratio: It delivers reliable protection without adding unnecessary weight, making it suitable for shipping and transportation solutions.

Long-term durability: XLPE foam maintains its properties over time and performs well in demanding environments.

Thermal and acoustic performance: In addition to thermal insulation, XLPE foam helps reduce noise and vibration for improved comfort and protection.

Fabrication versatility: XLPE foam can be cut, molded, laminated and fabricated into complex shapes and sizes to meet custom design requirements.

Applications of Cross Linked Polyethylene Foam

Construction: XLPE foam is used for pipe insulation, HVAC duct insulation, building insulation, floor underlayment and acoustic insulation because of its thermal and sound-dampening performance.

Automotive: It is used for gaskets, seals, vibration-damping parts, cushioning components and interior protective parts because of its durability, chemical resistance and long service life.

Packaging: Custom-fabricated XLPE foam inserts protect delicate, high-value and sensitive products during transportation. Anti-static grades can be used for electronic components and devices.

Fitness and recreation: XLPE foam is used in exercise mats, yoga mats, sports pads and protective equipment because of its comfort, resilience and moisture resistance.

Medical: It can be used in orthopedic supports, braces, prosthetic components and medical cushioning products where lightweight support and hygiene are important.

PE Foam Tool Box Insert

PE Foam Tape

PE Foam Rolls

Specific Uses for PE Foam and XLPE Foam

Cross linked polyethylene foam is widely used in packaging, surface protection, cold chain packaging, automotive parts, sports and leisure products, void fill, medical cushioning, construction insulation, military packaging, blocking and bracing, floor underlayment, recreation products, agriculture protection and archery targets.

Custom Foam Converting Capabilities

Topsun can convert XLPE foam into finished or semi-finished parts according to customer requirements. Our foam converting capabilities include cutting, slicing, lamination, laser cutting, die cutting, compression molding, engraving, silk-screen printing and adhesive backing.

1. Cutting: cut the foam size according to the customer’s request.

2. Slicing: slice the foam thickness according to the required specification.

3. Lamination: provide hot melt film lamination, flame lamination and pressure-sensitive adhesive lamination.

4. Laser cutting: cut foam drawings without opening molds.

5. Die cutting: open molds according to the customer’s design and produce foam parts efficiently.

6. Compression molding: manufacture three-dimensional molded foam and foam composite parts with defined geometry and dimensional requirements.

7. Engraving: produce tool box inserts and packaging inserts according to customer requirements.

8. Silk-screen printing: print logos and patterns on the surface of foam products.

9. Adhesive backing: apply adhesive and release liner to produce foam tapes and self-adhesive foam parts.

About Topsun Foam

Topsun is a professional foam supplier providing a wide range of foam products, including EVA foam, PE foam, XPE foam, IXPE foam, CR foam, EPDM foam, neoprene foam, SBR foam, NBR foam and micro-cell soft PVC foam. These materials can be supplied in sheet, roll and customized foam parts.

Our factory is located in Changzhou City, Jiangsu Province, about one hour by road to Shanghai Port. Topsun provides foam material selection, custom processing, sample support and OEM foam converting services for customers worldwide.

Crosslinked Polyethylene Foam FAQ

What is cross linked polyethylene foam?

Cross linked polyethylene foam, also known as XLPE foam or crosslinked PE foam, is a closed-cell polyethylene foam with improved cell stability, resilience, cushioning performance and durability. It is used for packaging, insulation, automotive sealing, sports padding and custom foam parts.

What is the difference between PE foam and XLPE foam?

PE foam is a general polyethylene foam material. XLPE foam is cross linked polyethylene foam, which usually provides a finer cell structure, better strength, improved resilience, better surface quality and stronger long-term durability for demanding applications.

Can XLPE foam be supplied in different densities?

Yes. Topsun can supply XLPE foam in different density grades such as PE25, PE30, PE40, PE45, PE60, PE90, PE120 and PE140. The suitable density depends on cushioning requirement, compression resistance, product weight, protection level and processing method.

Is XLPE foam waterproof?

XLPE foam has a closed-cell structure and very low water absorption, so it provides excellent moisture resistance. It is suitable for insulation, packaging, sealing and outdoor or humid environments where water resistance is important.

Can Topsun make custom die-cut XLPE foam parts?

Yes. Topsun can provide cutting, die cutting, laser cutting, adhesive backing, lamination, engraving and compression molding for custom XLPE foam parts. Customers can send drawings, samples or application details for quotation and sample preparation.

What industries use cross linked PE foam?

Cross linked PE foam is used in packaging, electronics, automotive, construction, HVAC, sports and leisure, medical products, cold chain packaging, floor underlayment, agriculture, military packaging and protective cushioning applications.

How can I get samples of XLPE foam?

Send your inquiry to july@topsunfoam.com with your required foam density, thickness, size, color, adhesive backing requirement, application and estimated order quantity. Topsun will check your requirements and reply within 24 hours.