Sports and fitness foam is the closed-cell polyethylene sheet behind yoga mats, gym mats, exercise mats, insoles, protective padding and equipment grips. It cushions impact, recovers its shape after compression and does not absorb sweat or water.
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?
Sports foam is a closed-cell cross-linked polyethylene sheet chosen for three properties at once: cushioning, dimensional stability and moisture resistance. Unlike open-cell foams, a sealed cell structure means the mat does not take on water, does not develop odour and keeps its cushioning in a gym or poolside environment.
- Cushioning and impact absorption — density and thickness are selected against the load the mat has to carry.
- Shape recovery — cross-linked foam springs back after compression instead of collapsing permanently.
- Grip and non-slip surface — the surface can be embossed to add texture.
- Water and sweat resistance — closed cells keep moisture out, so the mat can be wiped clean.
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
Irradiation cross-linked polyethylene foam, produced without a chemical cross-linking agent. Single layers go down to 0.1 mm, which suits insole layers, thin padding and laminates. It resists water, seawater, oils and alkalis, and is odourless — useful for products that sit against the skin.
Multi-Layer Laminates
Thicker mats are built by thermally bonding several foam layers, giving builds from 15 to 200 mm in XPE and up to 100 mm in the functional grades. Foam can also be laminated with non-woven fabric or a fabric facing for a textile feel.
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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) | ≤0.4% | ≤0.4% |
| Compression set, 23±2 °C / 22 h (GB/T 6669) | ≤10% | — |
| 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
- Yoga and exercise mats are usually built from lower-density XPE — the 25x to 40x range, roughly 26.8–40 kg/m³ — so the mat stays light and rolls easily.
- Gym and martial arts mats need more support and use higher densities, typically in the 10x to 20x range, at greater thickness.
- 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.
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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?
Most foam yoga mats are made from 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.
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?
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 must absorb.
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