Choosing between two types of foam can feel like deciding what type of jacket to wear—seemingly insignificant until you go outside and realize that there is, in fact, a correct answer.
However, choosing the wrong type of foam can have far more serious consequences than shivering all day. Using an ineffective foam could cause dangerous and expensive part failures.
Strouse has spent over three decades recommending product materials based on our clients' custom design needs.
If you want to know whether polyurethane foam or polyethylene foam is right for your intended use, keep reading to compare the differences.
Polyurethane and Polyethylene Foam
First, let’s compare these two foams to one another. Then, we’ll take a closer look at each of their individual material properties.
| Foam Type | Polyurethane (PU) | Polyethylene (PE) |
|---|---|---|
| Cell Structure | Open or Semi-closed cell | Closed cell |
| Characteristics | Flexible, softer & less dense | Stronger, more dense, waterproof & buoyant |
| Uses | Dust and moisture sealing, cushioning, thermal insulation, and noise insulation | Shock absorption, cushioning, noise and vibration insulation |
| Industries | Furniture, automotive, electronics, industrial | Medical, packaging, aerospace, sports, construction |
POLYURETHANE FOAM
Polyurethane (PU) foams, such as PORON foam, are often used in insulation and sealing solutions.
Due to their cushioning abilities, PU foams are popular for upholstery and other chair or mattress components. They are also sound-absorbing and offer thermal insulation, which contributes to automotive use cases.
OPEN AND SEMI-CLOSED CELL
Open-cell foams, like polyurethane, have more air pockets, making them lightweight, able to expand and conform, and better at soundproofing.
POLYETHYLENE FOAM
Polyethylene (PE) foams are often used in packaging, cushioning, and waterproof skin tape solutions. It’s a dense, moisture- and chemical-resistant material that is lightweight and shock-absorbing. PE foam is also commonly used in medical devices.
CLOSED-CELL
Closed-cell foam is more durable, tear-resistant, and longer lasting than open-cell alternatives. As a closed-cell foam, polyethylene is more resistant but also heavier than open-cell foam materials.
Choosing the Right Foam For Your Project
Both polyurethane and polyethylene foam are used in a wide range of applications, so your choice will ultimately depend on your project’s specific requirements.
For example, the thickness of foam may determine the best way to manufacture product components due to the challenges of achieving tight tolerances in thick materials like foam or rubber.
If you want to test different types of foam to see which suits your design, reach out today for precise samples. Strouse’s engineers will help guide you through the product development process to find the most cost-effective and optimized solution.
For more information on foam materials, see our Learning Center for additional resources.
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