10+ Types of Packaging Foam

Have you ever received a package with a broken item inside? That happens when the packaging doesn't provide enough cushioning.
It's something you wouldn't want for your business. Every business owner wants their products to arrive safely. It shouldn't matter whether you are shipping electronics or custom-made goods.
Packaging form is a good option for protecting your items during shipping. So, you need to settle on the right one to prevent returns, refunds, and unhappy customers.
Let's explore the different types of packaging available to help you choose the best one for your products.

What is a Packaging Foam?

Every product you ship needs protection. The last thing you want is a customer receiving a damaged item due to rough handling.
That's where packaging foam shines.
Packaging foam is the material that absorbs shock, reduces impact, and prevents scratches to ensure your fragile products arrive in perfect condition.

Why Use Packaging Foam?

Not every packaging material can provide the cushioning your product needs. Cardboard alone won't prevent breakage. And bubble wrap can't always absorb heavy shocks.
Would you trust a supplier who repeatedly sends you damaged goods? Your customers wouldn't either.
So, packaging foam gives you a reliable option for protection thanks to its lightweight, flexible, and impact-resistant properties.
These foams come in different forms to ensure you get what you want. Here are some of them:

• Form Sheets

These are the flat layers of protection that you can use to separate multiple items in a package, wrap around products, or line the inside of a box.
You can find them in different thicknesses. The thicker ones absorb stronger impacts as a protective barrier.

• Foam Rolls

The difference between these ones and sheets is that they are longer. You can use them to wrap large items.

• Foam Inserts

These are high-density foam molded or die-cut to fit specific products. Industries such as electronics, aerospace, and medical equipment manufacturing rely on foam inserts to protect high-value items.

• Form Blocks

You use these ones to add stability inside boxes or crates. Form blocks brace products inside a package to prevent movement and impact.

• Form Pads

Similar to blocks but thinner. They provide cushioning between stacked items or around corners.
Edges and some surfaces of items are always easily scratched no matter the packaging you use. That's where pads come in.

What Should You Look for in a Packaging Form?

The first and obvious factor to consider is the cost vs. protection. Is the form providing enough protection for its price? This helps you choose one that balances both.
But to know the level of protection a form offers, you may want to consider density and strength. Here, your choice will also depend on how heavy your items are.
Not every business sells regular-shaped items. This brings us to the third factor. Can the form be cut or molded to fit your products? How customizable
is it?
Your electronics need to arrive safely. And one way to ensure your packaging foam has anti-static properties. You can also consider the sustainability
of the packaging to appeal to eco-conscious customers.
With that said, here are the types of packaging foam you can use today.

1. Polyethylene Foam (PE Foam)

Source This is one of the most popular choices for protective packaging. Why? It's lightweight, flexible, and shock-absorbent. So, you get an ideal packaging foam to safeguard your fragile electronics, glassware, or medical devices during shipping.
You can get this form in densities ranging from just 20 kg/m³ to 145 kg/m³. I recommend the ones with higher densities if you want to protect heavier or more delicate products.
Thickness also varies. The common sizes are between 0.3 mm and 500 mm. What do you need? Is it sheets, rolls, or custom-molded forms? The answer depends on your packaging needs.

2. Polyurethane Foam (PU Foam)

Source: GTeek PU foam is also worth considering as it is soft, flexible, and designed to cushion delicate items during transit. The open-cell structure of PU foam is another thing to love about it. This type is able to absorb shock while remaining breathable.
Most brands use PU foam in custom inserts, case linings, and protective pads for electronics, medical devices, and sometimes glassware. It can conform to irregular shapes, and this makes it the perfect choice for businesses shipping sensitive products.

3. Expanded Polystyrene (EPS Foam)

Source: American Foam Products
EPS foam is another lightweight and rigid packaging material. You've probably seen it protecting electronics, appliances, or even food. But what makes it so effective?
This foam is made by expanding polystyrene beads and molding them into shape. Its closed-cell structure also ensures you don't worry about shock and moisture.

4. Extruded Polystyrene (XPS Foam)

Source: Foam Factory
XPS foam might be what you need if you are prioritizing durability and moisture resistance over anything else.
As we've said, EPS foam consists of small beads fused together. But extruded polystyrene foam is made through a continuous extrusion process. Why is this important? It is denser and provides superior strength and insulation.
Do you ship electronics, medical supplies, or perishable goods? The next time you are planning your shipment XPS foam may be a choice to prevent damage.
But that's not all. This foam cuts cleanly, so you can use custom-fit inserts to keep your products secure.

5. Anti-Static Foam

Source: ULINE
Electronics are delicate. One of the things that destroys them easily is electrostatic discharge (ESD). So, how do you protect your products from these invisible threats?
That's what anti-static foam is for.
This type of foam contains additives that prevent the buildup of static charges. It's usually in pink, but you can get it in black or even blue.
Listen to this:
There are two main types of anti-static foam: conductive and dissipative. The difference is brought by how they work.
Conductive foam has a resistance between 10³ to 10⁶ ohms and it redirects electrical charges away from the product.
The dissipative ones allow electrical charges to flow more slowly, so it works by reducing the risk of sudden discharges. Their resistance ranges from 10⁶ to 10⁹ ohms.

6. EVA Foam (Ethylene-Vinyl Acetate)

Source
EVA foam brings a rubber-like texture to product packaging. This one resists water, chemicals, or even UV radiation. It means you can use it for both your indoor and outdoor packaging needs.
The thickness ranges from 1mm to over 50mm, so you can choose the right level of protection for items.
I recommend this foam for electronics, medical devices, and custom case inserts. But you can also find it in sports equipment and footwear.

7. Cross-Linked Polyethylene Foam (XLPE Foam)

Source This one is a high-performance foam that offers most of the things the other types of packaging foam do, and more.
What I mean is that it resists chemicals, withstands repeated impacts, and doesn't break down easily. This makes it perfect for protecting sensitive products like electronics and high-end equipment.
It also offers thermal insulation, so there's less risk of damage from temperature changes.

8. Polypropylene Foam (PP Foam)

Source Are you looking for another foam that can handle repeated impacts without losing shape? PP foam might be it.
This form has:

• Excellent shock absorption
• High heat resistance
• Strong chemical resistance

You can use PP foam in automotive packaging, medical equipment cases, and reusable transport containers.
The other advantage is that polypropylene foam is easily recyclable. That way, its usage contributes to environmental sustainability.

9. Foam-in Place

Source
Do you want to ship oddly shaped, fragile, or high-value items that need extra protection? This is a good option.
Here is how it works:
You pour a liquid polyurethane mixture into a bag or directly into the shipping container. It then expands up to 200 times its original size. This way, it fills every gap and hardens into a shock-absorbing mold.
And you use only what's needed, so it reduces material waste. The only disadvantage is that it is more expensive than traditional packaging options. But the superior protection saves you money in the long run, so the choice is yours.

10. Biodegradable Foam

[caption id="attachment_6500" align="aligncenter" width="599"] Zwei im Fraunhofer WKI gefertigte Platten aus Holzschaum[/caption] Source 70% of shoppers consider sustainability when making purchasing decisions. That's why whether your packaging material is eco-conscious or not matters now more than ever.
You need an eco-friendly alternative to traditional foam. I mean one that can break down easily, unlike standard polystyrene, which can take hundreds of years to decompose.
The question most people ask on a subreddit I'm part of is whether biodegradable foam offers the same level of protection as others. We've used it, and it has done well in most cases. Some versions dissolve in water, so you don't have to worry about disposal.

11. Neoprene Foam

Source
Are you shipping items that need extra protection from moisture, impact, or extreme temperatures but want an option outside the already mentioned names?
This closed-cell foam might just give you exactly what you need.
Its thickness varies, and each one offers a different level of protection. Your electronics, medical instruments, and industrial equipment will benefit from neoprene's resistance.

12. Loose Fill Foam (Packaging Peanuts)

Source Have you ever opened a box and found it filled with small foam pieces? Those are packaging peanuts, but some call them loose-fill foam. They cushion fragile items to prevent damage during shipping.
You can choose between polystyrene peanuts and biodegradable starch-based ones. These pieces work by filling spaces. That's why you can use them for oddly shaped items.
Their only disadvantage is that they can create a mess. So, they may not be an option if you are trying to cut the extra waste.

Conclusion

You need the right packaging to ship products safely. But, the choice depends on your product, budget, and protection needed.
What type suits your needs best? Let us know.