Closed Cell Foam Converting

Closed Cell Foam Materials

We convert a range of closed cell foam materials to produce seals, gaskets, insulation, cushioning, and many other components. The closed cell structure — where individual cells are sealed — gives these materials low water absorption, resistance to moisture ingress, and good thermal insulation. We stock multiple foam types to suit different temperature ranges, firmness levels, and regulatory requirements.

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Material Properties and Benefits

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EPDM Foam

EPDM closed cell foam is available in densities from 70 to 330 kg/m³ across our range. It offers good resistance to UV radiation and ozone, making it well suited to outdoor and exposed environments. Operating temperatures range from −30°C to +100°C at constant use, depending on grade, with intermittent capability to +110°C. Water absorption is very low at 1–3%. Standard grades pass FMVSS302 flammability testing. A flame-retardant grade is available with UL94 HF-1 certification. All grades are CFC and HCFC free.

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Polyethylene Foam (Cross-linked PE / LDPE)

We carry several grades of closed cell cross-linked polyethylene foam with densities from 15 to 100 kg/m³. The material has very low water absorption (less than 1%), resistance to a wide range of chemicals, and low thermal conductivity from 0.034 W/mK at 10°C. Maximum operating temperatures range from 85°C to 105°C depending on grade. A flame-retardant grade is available, approved to UL94 HF-1 and aviation specification CS 25.853 / FAR 25.853. The material is chemically neutral and recyclable.

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Neoprene Foam

Neoprene closed cell foam is available at densities of 130–200 kg/m³. It offers good resistance to oil and weathering, with an operating range from −40°C to +100°C (intermittent). Compression set is very low — 1–3% at 25% compression after 24 hours recovery — making it well suited to sustained sealing applications. Both standard and flame-retardant grades are available; the FR grade passes UL94 HF-1 and FMVSS302. CFC and HCFC free.

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PVC Foam

Available at 120 and 200 kg/m³, PVC closed cell foam provides a practical balance of flexibility and firmness across a −30°C to +70°C operating range. Both grades pass FMVSS302 flammability testing.

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Elastomeric Foam – Kaiflex ST

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Kaiflex ST is a closed cell elastomeric foam based on synthetic rubber (flexible elastomeric foam, FEF). It is designed specifically for thermal insulation applications, with a thermal conductivity of ≤0.033 W/m·K at 0°C and a water vapour diffusion resistance factor (μ) of ≥10,000, so no additional vapour barrier is required. Service temperatures span −50°C to +85°C. Fire performance is rated Euroclass B-s3,d0 to EN 13501-1 and Class 0 to UK Building Regulations, with UL94 V-0 and HF-1 approval. It holds marine classification from DNV and Lloyd’s Register. The material is fibre-free, resistant to mould and microbial growth, and free from cadmium, lead, and formaldehyde.

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PORON® Polyurethane Foam

PORON 4701-series foam is manufactured by Rogers Corporation and available in Very Soft (4701-30) and Soft (4701-40) grades at densities from 240 to 480 kg/m³. It has an exceptionally low compression set — 2% maximum at 23°C — which means it reliably maintains sealing force over extended periods without permanent deformation. Recommended constant-use temperature is 90°C, with intermittent use to 121°C. The material resists UV, ozone, and mildew, and does not stain. It passes FMVSS302 and UL94 HBF flammability requirements.

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EVA Foam – Pakcel

Pakcel is a closed cell ethylene vinyl acetate (EVA) foam at 100–110 kg/m³. It has a Shore C hardness of 40–45 and operates from −40°C to +80°C. It is well suited to cushioning and protective applications where good energy absorption is needed.

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Silicone Foam

We convert silicone foam in several grades — from ultra soft to medium-firm — manufactured by Rogers Corporation (BISCO® series) and as a general-purpose closed cell silicone sponge (Grade 16). Silicone foam’s most distinctive characteristic is its very wide operating temperature range: down to −55°C to −60°C and up to +200°C at constant use, with intermittent capability to +250°C. This makes it suited to high-temperature sealing and insulation applications where other foam types cannot perform reliably.