Not all foam is created equal. If you’ve spent any time researching packaging options, shopping for protective gear, or even browsing craft materials, you’ve probably seen EVA foam and polyurethane (PU) foam mentioned frequently. They may look similar at first glance, but these two types of foam are like comparing apples to oranges — they have different properties and applications.
So, what is the actual difference between EVA and PU foam? And which one is right for your project?
As a foam packaging expert, we know the ins and outs of foam. Keep reading to discover the core differences between these two types of foam, and get our verdict on which one works best for packaging.
EVA foam, or ethylene-vinyl acetate, is a dense, rigid material that’s almost rubber-like in texture. This foam is flexible and often made from sheets. It’s often used in shoes, floor mats, crafts, and cosplay. Constructing products from EVA foam often involves cutting, sculpting, and using heat to form shapes in place. Once set, EVA foam will keep its shape.
Two cosplayers carry props that have been made using EVA foam, paint, and other materials. Photo by Muhammad Faiz Zulkeflee on Unsplash
This type of foam is excellent for these types of applications where a product will experience a lot of moderate repeat weight (such as shoes and floor mats) as well as in crafting applications where it can be formed into a desired shape. However, it has a very specific place in packaging applications because of those very same properties. It may squish, warp, or rip during transit.
Polyurethane foam is made by reacting polyols and isocyanates. It comes in both open-cell and closed-cell forms, which dramatically changes its properties. Most packaging foam made from polyurethane is open-cell, meaning it is softer and more compressible.
This product packaging features a custom polyurethane foam case insert.
For these reasons, polyurethane foam is one of the most often used for protective packaging materials.
Related Content: Benefits of Polyurethane Foam
EVA typically comes in thick blocks that are cut to size, but polyurethane is also available as a thin sheet wrap. Polyethylene sheet foam also works better in packaging applications, to wrap products for transit.
Related Content: Polyethylene Foam Sheets w/ 1m Barrier
|
Feature |
EVA Foam |
Polyurethane Foam (PU) |
|
Density |
Medium to High |
Low to Medium |
|
Texture |
Smooth, rubbery |
Softer, spongy |
|
Flexibility |
High flexibility and bounce back |
More compressible than flexible |
|
Common Uses |
Crafting, sports props, insoles |
Cushions, insulation, packaging material |
When it comes to protective packaging, polyurethane (PU) foam is the smarter and more versatile choice. Its lightweight, flexible, and cushioning properties make it ideal for protecting a wide range of products without adding unnecessary weight or cost.
EVA foam is better suited for direct-to-consumer products or crafting purposes. The high density and smooth texture of EVA foam make it a great material that can be cut, shaped, and burned to replicate other finishes but at a fraction of the weight. When it comes to protective packaging however, EVA doesn’t hold up.
Find Your Best Option with a Packaging Expert
As a leader in the packaging industry, Foam Industries has set the bar with an unwavering commitment to quality, exceptional client service, and constant innovation. Through our extensive inventory of endlessly customizable products, we ensure you find exactly what you’re looking for. Reach out to us today to get assistance finding a foam that best suits your packaging needs.
Foam Industries is a custom protective packaging company specializing in foam – with additional wood and plastic fabrication services. Our custom foam fabrication services are ideal for any type of packaging, display, or support service needed – from design to finished product.