What XPE foam is
XPE (cross-linked polyethylene) foam is a closed-cell foam whose polymer chains are chemically cross-linked before the material is expanded. That cross-linked network is what separates XPE from ordinary PE foam: it holds the cell structure under load, so the foam keeps its thickness and recovers after compression instead of collapsing. XPE is light and flexible, water-resistant, an effective thermal and acoustic insulator, and easy to cut, laminate, print and thermoform.
This page is the overview of the XPE family. For the mechanical property table and for ordering, see the XPE foam product page.
Grades in the XPE family
XPE is graded by expansion ratio, and the ratio fixes the apparent density - which in turn decides how firm the foam feels and how much load it carries. Shore hardness, tearing strength, water absorption and thermal conductivity for every ratio are on the product page; the index below is the one to start from.
| Expansion | Apparent density | Character |
|---|---|---|
| 3× | 300±40 kg/m³ | Rigid, board-like; the densest grade we make |
| 5× | 200±30 kg/m³ | Firm structural parts |
| 8× | 125±15 kg/m³ | Firm, general load bearing |
| 10× | 100±10 kg/m³ | The all-round grade |
| 15× | 66.7±8 kg/m³ | Firm but still flexible |
| 20× | 50±6 kg/m³ | Cushioning and padding |
| 25× | 40±4 kg/m³ | Soft cushioning |
| 30× | 33.3±3 kg/m³ | Soft and conformable |
| 35× | 28.6±2 kg/m³ | Very soft |
| 40× | 26.8±3 kg/m³ | The softest grade we make |
Choosing an XPE grade
| What the part has to do | Expansion | Apparent density | Single-layer thickness | Why this band |
|---|---|---|---|---|
| Protective packaging and void fill | 25–40× | 26.8–40 kg/m³ | 3–15 mm | Low density keeps weight and cost down where the part only has to be cushioned. |
| Case and tray inserts, tool foam | 15–25× | 40–66.7 kg/m³ | 3–15 mm | Firm enough to hold a part in a cut pocket without the pocket walls sagging. |
| Acoustic underlay and flooring | 20–30× | 33.3–50 kg/m³ | 3–15 mm | Closed cells damp vibration while the foam stays soft underfoot. |
| Impact and anti-collision padding | 10–20× | 50–100 kg/m³ | 3–15 mm (heat-bonded 15–200 mm) | High resilience under repeated compression, so padding keeps its cushioning instead of settling. |
| Structural and load-bearing parts | 3–8× | 125–300 kg/m³ | 3–15 mm | The dense grades carry load and hold their shape. |
How we supply XPE
- Expansion 3–40×, widths from 500 mm to 2000 mm
- Single-layer 3–15 mm; heat-bonded multilayer 15–200 mm
- Black, white, grey or custom colours
- Die-cutting, lamination, printing, thermoforming and adhesive coating
- Flame-retardant, anti-static, conductive and high-temperature grades - see the product page
XPE is one of three cross-linked families we make. Compare it with IXPE, which is irradiation cross-linked and therefore finer-celled and available thinner, and IXPP, which is polypropylene and takes a much higher service temperature. Laminated versions are collected under laminated materials. Contact us with the part and we will recommend a grade.
XPE foam specifications and custom parts · All foam materials · Request a quote
