The 3 Most Versatile Types of Foam

Foam is everywhere—your mattress, your car, your favorite gadgets—but not all foam is created equal. Whether you need cushioning, insulation, or protective packaging, the right type of foam makes all the difference. At Sterling, we specialize in three major types of foam, each with unique benefits. Want to know which one is best for your needs? Let’s break it down.

1. Expandable Polystyrene Foam (EPS)

Expandable Polystyrene Foam is made from small, round beads expanded by steam heat and molded into shape. It’s a closed-cell foam that is lightweight yet sturdy, making it an ideal choice for:

• Protective packaging – Crating, pile welding, pallet manufacturing, and packaging foam solutions that reduce shipping costs

• Insulation – Providing thermal insulation for buildings, protecting against heat transfer

• Specialty applications – Stage props, crown molding, and concrete forming

• Moisture-resistant solutions – Perfect for flotation devices and outdoor foam needs

EPS is a cost-effective, durable material with high shock absorption, making it a go-to option for industries that require lightweight packaging materials without compromising on protection.

2. Polyurethane Foam (PU)

Polyurethane Foam is an open-cell foam available in different densities, colors, and specialized forms. It’s one of the most versatile foam types and is commonly used in:

• Furniture & Bedding – Upholstery foam for couch backing cushions, mattress toppers, and orthopedic braces for pressure relief

• Consumer Applications – Memory foam for body support, soft foam for cushioning applications, and flexible foam for seating

• Medical & Industrial Uses – Highly resilient foam materials for medical devices, circuit boards, and demanding environments

• Sports & Fitness – Gym mats, yoga mats, and sports equipment that require durable foam with high shock absorption

There are also two main types of polyurethane foam:

• Polyether PU Foam: Found in everyday products like mattresses, pillows, and patio cushions. This soft foam conforms to the body’s shape and provides excellent support.

• Polyester PU Foam: A high-density, extremely firm foam with superior tensile strength. It’s commonly used in medical applications, packaging applications, and protective layers in industrial settings.

PU foam is an excellent choice for cushioning applications, providing long-lasting comfort and impact resistance.

3. Polyethylene Foam (PE)

Polyethylene Foam is a closed-cell foam that is available in two styles:

• Extruded: Manufactured as a single, uniform sheet for applications requiring durability

• Laminated: Layered sheets bonded together to create thicker foam for additional cushioning

PE foam is the workhorse of the packaging industry, offering superior impact protection and water resistance. It is widely used for:

• Electronic packaging – Protecting sensitive components like circuit boards, monitors, and hard drives

• Industrial applications – Custom foam sheets designed for automotive, aerospace, and high-density protective packaging

• Outdoor & Marine Uses – Neoprene foam and EVA foam (ethylene vinyl acetate) for flotation devices and water-resistant padding

• Medical & Sports Applications – High-density foam for orthopedic braces, medical applications, and shock-absorbing gym mats

PE foam’s closed-cell structure makes it resistant to water absorption, ensuring durability in outdoor and moisture-prone environments.

Which Foam is Right for You?

Unless you're brand new to our page, you'll know by now that we're big fans of foam. We fabricate it, we shape it, we design it, and we recycle it, too!

Sterling is ready to help you bring any sort of dream into a reality when it comes to foam manufacturing. Have questions? Need a quote? Contact us today and let’s talk foam!