If you make mats rather than buy them, the foam is the product. Cushioning, weight, roll-up behaviour, grip and how long the mat lasts before it flattens are all decided by the foam specification — and the two grades that matter are XPE and IXPE.
Bofeng Foam manufactures the foam sheet. We supply mat brands, converters and fitness equipment factories with XPE and IXPE in roll or sheet form; cutting, printing and assembly into a finished consumer mat are normally done by the brand or its converter.
Why Cross-Linked Foam for Mats
A mat is compressed every time it is used. Cross-linking gives the foam a three-dimensional molecular network, so it springs back instead of taking a permanent set. Our XPE is specified at a compression set of 10% or lower at 23 ± 2 °C over 22 hours — the property that decides whether a mat still cushions after a year.
Closed cells also mean the mat does not absorb sweat or water, does not develop odour, and can be wiped clean.
XPE or IXPE?
| Property | XPE | IXPE |
|---|---|---|
| Cross-linking | Chemical | Irradiation |
| 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 |
| Compression set (23 °C / 22 h) | 10% or lower | — |
XPE is the standard mat material. It is produced in single layers from 3 mm and laminated into thicker builds, and it takes embossing and printing well.
IXPE is used where a thinner, denser layer is wanted — a graduated insole, a thin travel mat, or a denser surface layer bonded to a softer core. Single layers go down to 0.1 mm.
Choosing Density and Thickness
- Yoga and travel mats sit at the low-density end — the 25x to 40x range, roughly 26.8 to 40 kg/m³ — so the mat stays light and rolls tightly.
- Exercise and pilates mats move up a step in density for more support without becoming heavy.
- Gym and martial arts mats use higher densities, typically the 10x to 20x range, at greater thickness, because they have to absorb a heavier impact.
- Thicker mats are built by thermally bonding layers, up to 200 mm in XPE.
Surface, Colour and Finish
Grip is a surface property, not a material one. Foam can be embossed to add texture, printed for branding or lamination, and supplied in black, white, grey or a custom colour. Where a textile feel is wanted, the foam is laminated with a non-woven or fabric facing.
Why Source the Foam From the 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 the density and thickness you qualify on a sample are the ones you receive on repeat orders.
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Mat Foam FAQ
What foam are yoga mats made of?
Most foam yoga mats use closed-cell cross-linked polyethylene — XPE, or IXPE where a thinner, denser layer is wanted. The foam is chosen for cushioning, shape recovery and the fact that it does not absorb sweat or water.
What density foam is best for a gym mat?
Gym and martial arts mats need more support than yoga mats and are typically built from the 10x to 20x expansion range at greater thickness. The right combination depends on the body weight and drop height the mat has to absorb.
Can Bofeng Foam supply finished mats?
We manufacture the foam sheet and can emboss, print and laminate it. Cutting and assembly into a finished consumer mat is normally carried out by the brand or its converter; we can discuss converting on a project basis.
Related Reading
See also: Sports & fitness foam hub · XPE foam density guide · All cross-linked foam materials · Contact Bofeng Foam