Foam sheet for sports mats, insoles and protective padding is selected for the finished construction and use. Compare cushioning, support, surface and cleaning requirements rather than assume a material grade establishes safety or hygiene.
Bofeng Foam manufactures XPE and IXPE foam sheet in Zhuhai, China and supplies it to mat brands, footwear makers and fitness equipment factories. We supply the foam material — cutting, printing, embossing and assembly of the finished mat are done by our customers or by agreement.
What is Sports and Fitness Foam?
Closed-cell foam has low, grade-specific water absorption. That is not zero uptake or proof of odour resistance, hygiene, non-slip performance or an unrestricted cleaning process. Check the actual facing, edges and cleaning exposure on the finished mat.
- Cushioning and impact absorption — density and thickness are selected against the load the mat has to carry.
- Compression-set limits for XPE and IXPE vary by ratio from ≤2% to ≤11% under GB/T 6669, 23±2 °C, 22 h. This is residual deformation in a defined test, not complete recovery, a cushioning service life or proof of performance after a year. Confirm the loaded mat and required ageing or impact tests.
- Embossing changes texture, but it is not a non-slip rating. Test the finished surface under the intended dry or wet contact and cleaning conditions.
- Water and sweat exposure require the selected grade, facing, seams and cleaning method to be confirmed. Low water absorption is not zero uptake or a hygiene result.
Foam Materials for Sports and Fitness Products
XPE Foam
Chemically cross-linked polyethylene foam, the standard material for yoga mats, gym mats and exercise mats. Expansion ratio 3–40x gives apparent densities from 26.8 to 300 kg/m³; single-layer thickness is 3–15 mm with laminated builds from 15 to 200 mm, in widths of 500–2000 mm, in black, white, grey or custom colours.
IXPE Foam
IXPE single-layer capability is 0.1–15 mm. Specify the layer thickness, grade, facing and contact requirements; those manufacturing ranges do not establish odour, hygiene or skin-contact approval.
Multi-Layer Laminates
Heat-bonded XPE and IXPE multi-layer ranges are 15–200 mm; IXPP is 6–100 mm. Confirm layer identity, total thickness, bond and finished-mat requirements rather than infer the whole mat result from a single sheet.
View laminated foam capabilities →
Sports and Fitness Foam Specifications
| Property | XPE | IXPE |
|---|---|---|
| Cross-linking | Chemical | Irradiation (electron beam) |
| Expansion ratio | 3–40x | 3–40x |
| Apparent density (GB/T 6343) | 26.8–300 kg/m³ | 26.8–300 kg/m³ |
| Single-layer thickness | 3–15 mm | 0.1–15 mm |
| Laminated build | 15–200 mm | 15–200 mm |
| Sheet width | 500–2000 mm | 500–2000 mm |
| Colours | Black, white, grey, custom | Black, white, grey, custom |
| Water absorption (GB/T 1034) | ≤0.2% to ≤0.4% | ≤0.2% to ≤0.4% |
| Compression set, 23±2 °C / 22 h (GB/T 6669) | Grade-dependent: limits from 2% or lower to 11% or lower; GB/T 6669, 23±2 °C, 22 h | Grade-dependent: limits from 2% or lower to 11% or lower; GB/T 6669, 23±2 °C, 22 h |
| Surface finish | Embossed or printed | Embossed or printed |
Mats that need more support are built from the lower expansion ratios — higher density — at greater thickness, and thick mats are produced by thermally bonding several layers. Foam can also be laminated with a non-woven or fabric facing.
Sports and Fitness Foam Products We Make
- Yoga mat foam
- Gym mat foam
- Exercise mat foam
- Martial arts mat foam
- Foam roller
- Athletic insole foam
- Sports protective foam
- Fitness equipment foam
- Archery target core foam
- Baby play mat foam
- Artificial turf pad foam
How Mat Makers Choose Density and Thickness
- Ratio and thickness are starting inputs. Specify the finished mat construction, contact load, movement, permitted deflection and intended impact or slip tests. Do not choose density from user weight alone or infer a safety rating from the foam grade.
- Ratio and thickness are starting inputs. Specify the finished mat construction, contact load, movement, permitted deflection and intended impact or slip tests. Do not choose density from user weight alone or infer a safety rating from the foam grade.
- Insoles and thin padding take IXPE, where a single layer can be as thin as 0.1 mm and several layers can be laminated to build a graduated sole.
- Surface finish is chosen for grip — embossing and printing are both available.
Why Choose Bofeng Foam as Your Sports Foam Manufacturer?
Bofeng Foam operates five production lines with an annual capacity of 5,000 tonnes from 10,000 m² of workshops in Zhuhai, China. Foam is produced, laminated and finished in-house, so a mat brand deals with one supplier for the material rather than sourcing foam and processing separately.
Request a sports foam sample or quote →
Ordering information
| Item | What we supply |
|---|---|
| Minimum order | 1,000 m² for standard rolls and sheets; custom parts are quoted individually from the drawing |
| Lead time | 15–20 days from order confirmation |
| Samples | A4 sheet, free of charge, shipping included |
| Supply forms | sheet, multi-layer laminate, die-cut mat core |
Sports and Fitness Foam FAQ
What foam are yoga mats made of?
Closed-cell foam has low, grade-specific water absorption. That is not zero uptake or proof of odour resistance, hygiene, non-slip performance or an unrestricted cleaning process. Check the actual facing, edges and cleaning exposure on the finished mat.
Can Bofeng Foam supply finished mats?
We manufacture the foam sheet itself and can emboss, print and laminate it. We die-cut, laminate and slit in-house; final assembly and branding of the finished mat stay with the brand owner.
Which density is used for gym mats?
Ratio and thickness are starting inputs. Specify the finished mat construction, contact load, movement, permitted deflection and intended impact or slip tests. Do not choose density from user weight alone or infer a safety rating from the foam grade.
Camping Mattress and Sleeping Pad Enquiries
If the requirement is described as a camping mattress or sleeping pad, state the full construction, packed format and required finished-product tests. Foam sheet, a picnic rug and a rated sleeping system are different scopes. We can review the material and converting request; a sheet conductivity value is not a declared sleeping-pad thermal rating.
Related Reading
See also: XPE and IXPE foam for yoga mats and gym mats · XPE foam density guide · All cross-linked foam materials · Contact Bofeng Foam