Polyethylene (PE) Foam Packaging Solutions

Our most popular foam! Polyethylene Foam is low cost, resilient to chemicals and water, and industrially recyclable. It’s suited for a wide variety of applications - end caps, case inserts, and other common types of packaging.

If your product needs lightweight, durable protection that holds its shape and ships efficiently, polyethylene foam is often the right starting point.

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Why Polyethylene Foam Works for Protective Packaging

Polyethylene foam is ol' reliable. It works hard, and it does the job for basic packaging needs.

If polyethylene foam is not the right solution, we will say so. The goal is protection that works, not forcing a material.

Benefits of Polyethylene Foam

Sustainable - made from recycled materials and can be recycled after use
Fast and Easy to fabricate and bond
Chemical resistant
Water resistant
Can be heat bonded
Wide variety of densities and color

Common Applications

Protective inserts for industrial and manufactured products
Lightweight packaging for large or fully assembled items
Cushioning for vibration and drop protection
Reusable or returnable packaging systems
Shipping protection where moisture resistance matters
Direct-to-consumer packaging

Industries Served

Industries

Industrial

Medical

Automotive

Aerospace & Military

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Branding & Marketing

Fixtures & Displays

Check out the many applications of Polyethylene Foam with some of our past projects.

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Why Choose Foam Industries for Polyethylene Foam Packaging?

We design and fabricate custom polyethylene foam packaging based on your product, the risk profile, and the shipping environment. It's not one-size-fits-all. It's a custom, FastAF solution for your needs.

We focus on stable lead times, predictable costs, and repeatable results across every run. And, we like to have a bit of fun while we're at it.

Data-backed production with quality checks.
Reliable sourcing for all materials.
Quick-turn prototypes or large-volume runs: scale at your pace.
A commitment to sustainable manufacturing.
A creative team that aren't afraid to problem solve.
Proactive communication, and one main point of contact for each project.

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Frequently Asked Questions

How do I know if polyethylene foam is the right option?

Our team evaluates your product, shipping method, and risk factors to determine whether polyethylene foam is appropriate or if another packaging approach would perform better.

What’s the difference between polyethylene foam and other packaging foams?

Different foams behave differently under impact, compression, and vibration. Polyethylene foam is known for durability and moisture resistance, while other foams may offer softer cushioning or different recovery characteristics. The right choice depends on the product and shipping conditions. We'll help you make the right decision for your application.

Can you work from existing packaging designs?

Absolutely. We can replicate, adjust, or fully re-engineer an existing design. Many clients come to us looking to reduce cost, improve protection, or streamline assembly.

I have a product but I need a design for a package. Will you create something for me?

Our strength is working with your design teams to create something even better. We do review existing designs for manufacturability, cost-effectiveness, and performance. We typically do not provide full-scale design and engineering services for brand new products. However: our team also doesn't shy away from a challenge. If you are looking for more heavy-duty design support, please still reach out. While it's not a core service, it is something we have provided on a case-by-case basis.

Do you sell raw materials?

We do not. We source a wide range of closed-cell and open-cell foams, primarily from our partner Pregis. Other suppliers include:

What are your sustainability initiatives?

We support sustainable manufacturing and supply chain logistics by smart material selection, post-production recycling, and consumer education. You can dive into our sustainability initiatives on our Sustainability Packaging page.

Do you build full packaging systems or only foam?

Foam is our specialty, but we also build hybrid systems that use corrugated, plastics, custom wood components, and sewn parts when the design calls for it. On occasion, completed projects don't involve foam at all. If your goal is to get something from A to B without damage, to provide a bespoke kit, or optimize transportation, reach out to us!

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