Keeping fragile products safe during transport is a challenge every manufacturer faces. Electronics, medical devices, glassware, engineered components, and other high-value parts require reliable packaging that prevents breakage, absorbs shock, and protects against moisture and vibrations. Foam packaging has become a top choice because of its strength, lightweight design, and ability to be shaped around nearly any product.
Sterling Manufacturing & Distributing uses polyurethane, polyethylene, and expanded polystyrene foam, delivering both raw materials and finished protective solutions. From military to oil and gas to automotive, furniture, construction, and medical applications, Sterling brings decades of knowledge and fabrication expertise to every industry to help match the right foam to their packaging needs.
In this guide, you will learn how foam packaging works, the strengths of each major foam category, and how to choose the ideal option to protect fragile shipments.
Foam packaging materials are engineered to cushion products during transport. Closed-cell or open-cell structures provide consistent shock absorption, protecting delicate equipment against drops, movement, and unexpected impacts. Foam is also lightweight, which helps reduce shipping costs without compromising durability.
Both Polyethylene and Polyurethane foams can be fabricated into inserts, pads, dividers, or fully custom shapes. This gives manufacturers the flexibility to protect everything from simple square components to complex multi-part assemblies. EPS foam is also widely used in rigid protective structures for space filling, support, or insulation.
Did You Know? Foamex explains that expanded polystyrene (EPS) is a lightweight, cost-efficient packaging material that offers strong insulation, shock protection, and moisture resistance. It can be custom-molded, easy to handle, and supports lower shipping costs compared to heavier alternatives. EPS is also recyclable, durable, and well-suited for protecting products in transit.
Polyethylene foam combines strength, flexibility, and water resistance. It is durable enough for repeated handling and does not scratch delicate surfaces. PE foam also performs well in applications that require chemical resistance or clean environments. This material is popular for parts that are sensitive to vibration, impact, or static.
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PE foam is available in a range of densities, which allows packaging engineers to achieve either soft cushioning or more rigid impact control. Because the material is clean and non-abrasive, it is an ideal match for sensitive products that must arrive in perfect condition.
Sterling Manufacturing provides polyethylene foam in sheets, rolls, and customized configurations to support a wide range of applications. From surface protection and buoyancy components to anti-static requirements, our team can supply the right foam solution tailored to your needs.
Polyurethane foam offers high versatility. It can be cut, molded, or shaped into precise contours for components that require tight fit protection. PU foam is widely used for product inserts because it can cradle irregular shapes and reduce motion inside containers.
Two common types exist: polyether and polyester. Polyether foam is resilient, flexible, and breathable. Polyester foam is more resistant to tearing and abrasion. Both can be engineered in multiple densities, colors, and performance ratings, including anti-static variations.
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Did You Know? The American Chemical Council states that rigid polyurethane and polyisocyanurate foams help improve building efficiency by stabilizing temperatures and reducing energy loss. Since heating and cooling account for about 56 percent of a typical U.S. home’s energy use, these foams are widely used in walls, roofs, and insulation systems to lower costs and enhance comfort.
At Sterling Manufacturing & Distributing, we focus on quality and have earned long-term customer partnerships, supported by a wide range of fabrication capabilities, including automated contour cutting, precision blade cutting, and hot wire applications.
Expanded polystyrene foam is a rigid, lightweight material used for structural packaging and shock distribution. It is commonly used to brace larger equipment, fill voids, stabilize products, and protect items that are bulky or irregular in shape.
EPS is naturally moisture-resistant and insulative, which helps maintain stable conditions during transit. It is also cost effective, making it a popular choice for larger volume packaging projects.
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EPS is valued for its closed-cell structure, which provides strong thermal insulation and a high R-value, making it effective in construction, refrigeration, and packaging. Its lightweight nature helps lower transportation costs, while resistance to moisture, chemicals, and pests adds to its durability. These combined properties make EPS a reliable and versatile material across multiple industries.
Selecting the correct foam packaging starts with understanding the properties and risks of your product. The more fragile the item, the more customization and softness you may need. If a component is heavy or prone to shifting, you may require stronger, more rigid material.
Here are useful questions to begin the decision process:
Glass, electronics, or medical instruments often benefit from polyurethane or polyethylene foam because these materials can be machined or molded for a precise fit.
Polyethylene foam and EPS both offer moisture resistance, making them useful for environments with condensation, fluids, or temperature change.
Polyethylene foam is commonly used in electronics because it provides vibration control and can be formulated with anti-static protection.
Polyethylene foam is durable and long-lasting, which can reduce packaging replacement costs over time.
EPS foam supports larger mass and volume, especially for items that do not require soft cushioning.
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Foam Type |
Key Properties & Benefits |
|
Polyethylene (PE) foam |
Durable, moisture and mildew resistant, chemical resistance, lightweight, shock absorption |
|
Polyurethane (PU) foam (Ether & Ester) |
Highly versatile, available in many densities/colors. Soft, flexible, or rigid based on density. |
|
Expanded Polystyrene (EPS) foam |
Lightweight, rigid, moisture-resistant, good for rigid inserts or as void-fill. |
When in doubt, engineered mock-ups or prototype fitments can be the most reliable way to test packaging results. Sterling regularly supports customers with samples, consultations, and foam recommendations based on industry standards and shipment conditions.
Foam packaging is one of the most reliable ways to protect fragile products during shipping. The compressive strength, impact resistance, and custom fit options offered by polyethylene, polyurethane, and EPS foams make them ideal for today’s complex supply chains. Evaluating your product’s fragility, the shipping environment, storage conditions, and long-term use will help guide the choice of foam solution.
If you are exploring packaging options for a new product or reviewing current protection systems, our team is here to help. Contact Sterling Manufacturing & Distributing to request a consultation or material sample.