At Sterling Manufacturing, we’ve been at the forefront of foam fabrication for over 50 years, serving a wide array of industries with our custom foam solutions.
As a leading foam fabricator based in Houston, Texas, we understand that choosing the right type of foam for your specific application can be crucial to your project’s success.
“The development of foam packing has been characterized by an ongoing search for innovation to satisfy changing industry demands,” says a research report released in May 2024. “The market has seen a radical shift from conventional Styrofoam blocks to custom-molded foam inserts, propelled by developments in material science and production technology.”
In this article, we’ll dive into the various foam options available and explore their unique properties and applications.
Before we delve into specific foam types, it’s essential to understand the pivotal role that foam plays in the world’s supply chain.
Foam materials have become an indispensable component in numerous industries, significantly impacting how products are manufactured, packaged, and transported.
In fact, the global foam packaging market is projected to almost double in value between 2023 and 2031, going from $18.32 billion to $29.28 billion.
Key contributions of foam to the global supply chain:
From the factory floor to the end consumer’s hands, foam materials are integral to maintaining the integrity and efficiency of global supply chains. As we explore different foam types, keep in mind how each contributes to this larger picture of worldwide product distribution and protection.
Polyurethane foam is a true jack-of-all-trades in the world of foam materials.
The polyurethane Sterling supply’s, primarily Ether and Ester, is an open-cell foam that is available in various densities and colors for your unique applications. In addition to the standard foam, we also offer specialty foams like anti-static and anti-abrasive for specific applications.
At Sterling Manufacturing, we specialize in two main types of PU foam: Ether and Ester.
EPS foam is a versatile material known for its lightweight and rigid properties. EPS foams are easily fabricated into shapes for protective packaging.
Let’s explore what makes this foam unique:
Polyethylene foam is a go-to material for the packaging industry, offering excellent protection for a wide range of products. Considered the workhorse of the packaging industry, there are several types of PE foam available, manufactured in various ways.
Types include extruded (full sheet manufactured in one piece no matter the thickness) and laminated (desired thickness by layering several sheets of half or one-inch pieces together).
| Foam Type | Density Range (lb/ft³) | Key Properties | Best For |
| PU Ether | Varies | Versatile, open-cell structure | Furniture, bedding, automotive |
| PU Ester | 1.3 – 6 | High strength, abrasion-resistant | Medical, acoustical, filtration |
| EPS | 0.7 – 3 | Lightweight, rigid, moisture-proof | Packaging, insulation, construction |
| PE | 0.7 – 9 | Excellent cushioning, non-abrasive | Packaging, electronics protection |
While not a distinct foam type, foam cubes deserve special mention due to their unique applications in recreational and sporting facilities. At Sterling Manufacturing, we offer a range of vibrant, high-quality foam cubes perfect for:
Our foam cubes are:
The world of foam is vast and varied, with each type offering unique properties suited to different applications. At Sterling Manufacturing, we pride ourselves on our expertise in foam fabrication and our ability to recommend the perfect foam solution for your specific needs.
Whether you’re in the furniture industry, packaging sector, or building a state-of-the-art recreational facility, we have the knowledge and resources to support your project from concept to completion.
Ready to explore the perfect foam solution for your next project?
Contact us today at 713-695-5333 or visit our website to discuss your foam requirements.