PE Foam EVA Foam with Heat Lamination

PE Foam EVA Foam with Heat Lamination

TOPSUN supplies cross-linked polyethylene foam and PE foam laminated with EVA foam for protective case inserts, industrial packaging, tool organization, automotive components, construction insulation, seals, pads and other custom applications. Heat lamination combines multiple foam layers without relying solely on liquid adhesive, helping create thicker, multi-density or multi-color foam structures for CNC routing, die cutting and compression molding.

The closed-cell structure provides low water absorption, good cushioning, thermal insulation, chemical resistance and dimensional stability. PE foam and EVA foam can be selected by density, hardness, thickness, color and surface finish to match the required impact protection, appearance and processing method.

Key Features of Cross-Linked PE Foam

• Lightweight and resilient: provides cushioning while adding limited weight to cases, packaging and fabricated parts.

• Impact and shock absorption: helps protect tools, electronics, instruments and other products during handling and transportation.

• Closed-cell moisture resistance: absorbs very little water and helps resist moisture-related deterioration.

• Thermal and acoustic insulation: the fine cell structure helps reduce heat transfer, vibration and sound transmission in suitable assemblies.

• Chemical resistance: offers resistance to many acids, alkalis, oils and common industrial chemicals.

• Non-abrasive surface protection: helps reduce scratching, denting and surface damage when an appropriate grade is selected.

• Easy fabrication: suitable for cutting, laminating, routing, engraving, die cutting, molding and adhesive conversion.

PE Foam and EVA Foam Heat Lamination

Heat lamination bonds compatible PE and EVA foam layers by controlled heating and pressure. The process can produce multilayer foam blocks with different densities, colors or functional layers. These blocks can then be converted into custom case inserts, tool trays, packaging supports, gaskets and molded components.

A harder PE or EVA layer can provide shape retention and load support, while a softer layer can improve cushioning and contact protection. Contrasting colors can also create a visual tool-control system: when a tool is removed, the lower layer becomes visible.

Advantages of Multi-Layer Foam Lamination

• Combines different densities and hardness levels in one foam structure.

• Creates thicker blocks for deep CNC-routed cavities and equipment cases.

• Supports dual-color or multi-color tool organization and visual inventory control.

• Allows the surface layer and support layer to be optimized separately.

• Can be combined with adhesive backing, films, fabrics or other compatible facings.

Cross-Linked Polyethylene Foam Specifications

The following values are typical test results for TOPSUN PE foam grades. Actual performance may vary with formulation, color, thickness, test conditions and production tolerance. Confirm the final technical specification before ordering.

What Is PE Foam?

TOPSUN PE Foam Process Flow

Benefits of PE Foam

Wide Density and Hardness Range

PE foam is available from lower-density cushioning grades to higher-density structural grades. This allows the firmness, support, cut quality and compression resistance to be matched to the product weight and protection requirement.

Resilience and Impact Protection

The material absorbs impact energy and recovers after compression, making it useful for reusable packaging, transport cases, protective padding and blocking-and-bracing systems.

Thermal and Moisture Performance

The closed-cell structure helps limit heat transfer and water absorption. PE foam is therefore used in thermal packaging, pipe insulation, construction joints, floor underlayment and other environments where moisture resistance is important.

Chemical and Environmental Resistance

Cross-linked PE foam resists many chemicals, oils and solvents and does not readily support mold or mildew. Suitability should still be confirmed against the actual chemical concentration, temperature and exposure duration.

Buoyancy and Low Weight

Its low density and closed-cell structure provide buoyancy for marine, sports and recreational components while keeping the finished product lightweight.

Applications of PE Foam and EVA Foam

Protective Packaging and Case Inserts

Custom PE and EVA foam inserts protect tools, electronics, test instruments, medical devices, optics and other sensitive products. CNC-routed cavities can be produced from customer drawings, CAD files or physical samples.

Construction and Insulation

PE foam can be used for expansion-joint fillers, sill gaskets, floor underlayment, insulation boards, pipe insulation, sealing strips and vibration-isolation layers. The complete assembly must be designed according to the relevant thermal, fire and building requirements.

Automotive and Transportation

Applications include interior padding, seals, gaskets, anti-rattle pads, acoustic layers, vibration-control components and protective transport packaging.

Medical and Healthcare

Selected foam grades can be converted into orthopedic padding, positioning supports, equipment-case inserts and medical-device packaging. Required compliance and skin-contact specifications must be confirmed before material selection.

Sports, Recreation and Marine

PE and EVA foams are used in exercise mats, flotation components, protective sports padding, targets, pool products, boat components and recreational cushioning.

Electronics and Industrial Components

Converted foam parts can provide cushioning, spacing, sealing, insulation and vibration control for electronic devices, cabinets, machinery and precision instruments. Antistatic or conductive performance should be specified where electrostatic control is required.

Specific Uses for PE Foam

Common uses include protective packaging, surface protection, cold-chain packaging, automotive components, sports and leisure products, void fill, medical supports, construction seals, military cases, blocking and bracing, floor underlayment, agriculture products, archery targets, flotation parts, tool-control inserts and adhesive foam tapes.

Custom PE Foam Processing Capabilities

Cutting and Thickness Slicing

Blocks, sheets and rolls can be cut to the requested length and width, then sliced to the required thickness within the applicable manufacturing tolerance.

Heat, Flame and Adhesive Lamination

Available lamination methods include heat lamination, hot-melt film lamination, flame lamination and pressure-sensitive adhesive lamination. The process is selected according to material compatibility, bond strength, temperature exposure and end use.

CNC Routing and Digital Cutting

CNC equipment can produce cavities, profiles, channels and custom contours directly from digital drawings, making it suitable for prototypes, tool inserts and complex low-to-medium-volume parts.

Die Cutting

Steel-rule or custom tooling can produce repeatable foam pads, seals, gaskets and inserts efficiently for medium-to-high-volume production.

Compression Molding and Thermoforming

Three-dimensional foam and foam-composite parts can be molded where defined geometry, contoured surfaces, variable wall thickness or dimensional control is required.

Engraving, Printing and Adhesive Backing

Foam surfaces can be engraved or screen printed with logos, labels and tool positions. Pressure-sensitive adhesive and release liners can be added for installation-ready tapes, pads and seals.

Why Choose TOPSUN as Your PE Foam Supplier?

TOPSUN supplies and converts EVA foam, PE foam, XPE foam, IXPE foam, CR foam, EPDM foam, neoprene foam, SBR foam, NBR foam and microcellular PVC foam. Materials are available in sheets, rolls, blocks and finished custom parts.

• Multiple PE foam densities and hardness levels for cushioning or structural support.

• PE-to-EVA and multilayer foam heat-lamination capability.

• CNC, die-cut, molded and adhesive-backed custom components.

• Support for material selection based on density, hardness, compression and end-use conditions.

• Sample and prototype evaluation before bulk production.

Our facility is located in Changzhou, Jiangsu Province, with convenient access to Shanghai Port for international shipments.

PE Foam and EVA Foam FAQ

What Is the Difference Between PE Foam and EVA Foam?

PE foam is generally lightweight, moisture resistant and available across a wide density range. EVA foam typically provides a softer feel, flexible resilience, good color options and strong suitability for molded or precision-cut parts. The better material depends on cushioning, hardness, appearance, temperature, chemical exposure and processing requirements.

Can PE Foam and EVA Foam Be Heat Laminated Together?

Yes. Compatible PE and EVA foam grades can be heat laminated into multi-layer structures. A production trial may be required to confirm bonding performance because foam formulation, surface condition, density and operating temperature affect the result.

Which Foam Density Is Best for a Custom Case Insert?

Lower-density foam provides softer cushioning, while higher-density foam offers greater load support, cleaner machining and improved shape retention. Many inserts use multiple densities: a firm base or structural layer combined with a softer contact layer. The product weight, drop risk, cavity depth and case dimensions should be reviewed before selection.

Is Cross-Linked PE Foam Waterproof?

Cross-linked PE foam has a closed-cell structure and very low water absorption, making it suitable for moisture-resistant cushioning, insulation and flotation applications. However, fabricated joints, cut edges and the complete product assembly still need to be designed for the actual exposure conditions.

Can TOPSUN CNC-Cut Foam from a CAD Drawing?

Yes. CNC routing and digital cutting can produce custom cavities and contours from suitable CAD files. Provide the file format, finished dimensions, tolerance, cavity depth, foam specification and expected quantity for review.

Can PE Foam Be Supplied with Adhesive Backing?

Yes. Pressure-sensitive adhesive and release liner can be laminated to one or both sides. The adhesive should be selected according to the substrate, temperature range, humidity, expected service life and required peel strength.

Is PE Foam Suitable for Thermal Insulation?

The listed PE foam grades have typical thermal conductivity values of approximately 0.037–0.038 W/m·K. Suitability depends on thickness, temperature, assembly design and the required thermal resistance. Confirm the test method and final grade for insulation projects.

Is PE Foam Fireproof?

Standard PE foam should not be described as fireproof. Flame-retardant grades may be available for specific test methods, but the required standard must be supplied before material selection. Final compliance can depend on foam thickness, density and the complete product assembly.

How Do I Request Samples and a Quotation?

Email july@topsunfoam.com with the foam type, density, hardness, thickness, size, color, quantity, processing method and destination country. For custom parts, include a drawing, CAD file or physical sample. TOPSUN will review the specification and provide sample and quotation details.