Plastazote Foam Fabrication

Advanced Seals & Gaskets Ltd pride itself on being able to work with a multitude of reputable material manufacturers and suppliers, enabling us to offer fabricated components using a range of materials in many grades, densities and colours.  Our more popular materials include various types of Polyethylene (PE) foam, one of which is Low-Density Plastazote foam in densities ranging from 15kg to 70kg (referred to as LD15, LD33, LD45, LD60 or LD70 respectively). 

This material is a closed-cell, cross-linked polyethylene foam which is incredibly lightweight, and free from chemical agents which enable customers to use this material in highly sensitive environments. A fabrication requires specialist machinery, usually a combination of saws, drills, buffers and knives. By choosing ASG for your fabrications, you will also benefit from the option of using our CNC oscillating knife, which can automatically buff, cut and drill fabricated parts by reading CAD drawings. 

Foam fabrications are often used as a cheaper alternative to mouldings and extrusions (as there is no initial die/tooling cost) for the production of bespoke shapes, usually required as 1 off prototypes or small quantity runs.  All our fabrications are made to order and are produced using samples or drawings provided by customers, and can take many forms for example multiple material laminating to create composites sheets which are then cut down into gaskets, washers, strips, displays & signage (such as logos/lettering), props, costumes and seals with flexible joints or irregular angles.

What are Plastazote Foam Fabrications?

Plastazote foam is a cross-linked, closed-cell polyethylene foam, man-made using crude oil into which nitrogen is blown and the foam is expanded. This manufacturing process produces a tough and flexible material.  When the plastazote foam has compressed each nitrogen-filled cell acts like a balloon, causing the foam to bounce back to its original shape. Being a closed-cell structure of plastazote means it is impenetrable to air and moisture and will not allow liquids to pass through or be absorbed.  

Fabrication is the procedure of turning blocks or sheets of foam into custom made 3D usable shapes. Fabrications are created using a combination of CNC machines, saws, drills, buffers etc, enabling us to create unique products that usually cannot be produced by one single process such as press, where the item is too big to be produced in one single piece, or where 3D profiles are required such as cubes or cone shapes. 

Supplying fabricated parts also allows us to produce composite sheets (laminating multiple layers of different materials together), before cutting out the final shapes.

Plastazote Foam Fabrication

Product Enquiry

For information on Plastazote Foam Fabrication please complete the following quick enquiry or call us on +44(0)1384 252555.






    Product Specification & Key Characteristics

    • Colours: Black and white as standard (red, blue, yellow and green, pink, etc) can be supplied upon request
    • Density: 15kg - 70kg
    • Cell Structure: closed-cell
    • Temperature Range: -70 - +105

    Full technical data can be supplied upon request,
    or downloaded from our online portal.

    Help and guidance

    If you would like to speak to a representative to discuss your specific application or requirements please call our sales office direct on 01384 469100, alternatively you can send an E-mail. Simply click on the link and forward us your details along with your question and we will contact you immediately.

    Samples - Technical Plastazote Foam Fabrication

    Samples can be submitted for testing upon request.

    Call now for sample requests or further help.

    Why use Plastazote Foam Fabrications?

    Plastazote foam is a very low-density foam that can be easily split, cut and shaped.  Even with such low density, it still offers excellent compression following compression and impact.  It offers resistance to a range of chemicals, solvents, acids, alkalies and some oils, meaning it can be utilised in many applications. 

    All Plastazote materials are lightweight and free from chemical agents, therefore can be used in many ‘clean’ applications such as food, pharmaceutical and science.  Advanced Seals & Gaskets Ltd have a team dedicated to fabrications and the production of one-offs and complex products to use during design and prototype development or when singular items are required. 

    Fabrications are often used as a cheaper alternative to mouldings and extrusions (as there is no initial die/tooling cost) for the production of bespoke shapes, these are ideal for use as samples or prototypes prior to paying for expensive tooling for mouldings or extrusions for bulk production. 

    The material is generally more coarse and rigid in comparison to other foams and sponges, which make them easier to cut or carve into irregular shapes making it perfect for producing props, signs, displays, packaging case/box inserts with routered out shapes to hold specific items in place.

    Advantages of using Plastazote Foam Fabrications

    Using Plastazote foam offers countless advantages and is highly utilised in numerous industries and applications,  Plastazote foam is a man-made material, designed to suit a range of requirements and is available in a choice of grades, densities and colours to suit.  Plastazote foams are odourless, lightweight, buoyant, non-toxic and offer resistance to many oils, solvents, acids and alkalis.  

    Its closed-cell surface does not allow the absorption of liquids and is easy to keep clean, as well as being weatherproof and UV stable.  Plastazote foam fabrications offer a range of benefits, not only are they more cost-effective, but they also enable us to produce a number of variations of the same product for testing, allows us to produce composite materials which add extra mechanical properties and resistance to the product and also allows to offer products for even the most unique applications.

    Typical Applications for Plastazote Polyethylene foam:

    Plastazote polyethylene foam is most commonly found used in packaging applications, being low density, plastazote can be easily cut and manipulated to fit around delicate or fragile products.   Other applications can include:

    • Making costumes or props
    • Displays
    • Used in the manufacture of sports equipment 
    • Water repellent and buoyant for use as floatation or buoyancy aids
    • Used for surface protection and components for medical and healthcare applications
    • Footwear lining
    • Electronics packaging

    Benefits of using Plastazote foam

    • Lightweight & durable
    • Good impact and shock absorbing properties
    • Water repellent and buoyant
    • Excellent chemical, oils, acids, alkalis and solvent resistance
    • Good thermal insulation
    • Non-toxic and low odour
    • Easy to cut, convert  & shape

    Different Grades of Polyethylene Foam

    Having a network of manufacturers and suppliers, allows ASG to offer a full range of polyethylene materials, many of which are readily available from stock for a quick turnaround.  Below is just a selection of some of our popular polyethylene material types we can offer:

    • Polyethylene (Block foam)
    • Anti-static
    • Ethafoam
    • Eva foam
    • Flame retardant
    • Chemically cross-linked 
    • Low Density (LD) Plastazote (densities from 15kg to 70kg)
    • High Density (HD) Plastazote (densities from 30kg to 130kg)
    • Stratocell
    Have a Question about Plastazote Foam Fabrication?

    Please contact us using the form below or by calling us on +44(0)1384 252555.