Foam materials play a critical role in the performance, comfort, and effectiveness of orthotic and prosthetic devices. The right foam can make the difference between a device that supports healing and mobility, and one that causes discomfort, skin irritation or mechanical failure.

In orthotic design, foam is often used for cushioning, pressure redistribution, and shock absorption, especially in footbeds and bracing systems. In prosthetics, foam is essential for interface liners, socket padding, and cosmetic finishing, helping to reduce shear forces and improve wearer comfort. Each clinical need-from diabetic foot ulcers to high-impact prosthetic use-requires a specific balance of properties such as density resilience, moldability, and moisture resistance.

Choosing the right foam ensures optimal biomechanical support while protecting skin integrity and maximising patient compliance, all of which are key to successful outcomes in O&P care.

The material used for orthotic and prosthetic devices directly influences how well the device performs and how comfortable it is for the user. Each form type offers distinct properties that affect several critical aspects:

Comfort – soft, conformable foams like Plastazote, and PORON reduce pressure points, absorb shock, and help prevent skin breakdown, especially important for users with sensitive skin or at-risk skin.

Function – the right material enhances biomechanical alignment and support. For instance, high-density EVA provides firm structural support in foot orthoses, while more resilient foams improve shock attenuation in prosthetic liners.

Durability – foams vary in how well they hold up under repeated stress. Materials like EVA and PE (polyethylene) offer excellent wear resistance, making them suitable for active users or high-load areas. In contrast, some softer foams may compress or degrade faster if not properly matched to the application.

Ultimately, precise material selection leads to more effective, personalised care, supporting both the short-term goals of comfort and the long-term goals of function and health.

When it comes to sourcing reliable, medical-grade materials for orthotics and prosthetics, Algeos stands out as a leading supplier trusted by clinicians, technicians, and healthcare providers worldwide. With decades of experience in the O&P field, Algeos offers an extensive range of specialised foams designed to meet the unique demands of patient care, from everyday orthotic inserts to high-performance prosthetic interfaces.

Our product line includes industry-standard materials like Plastazote, Evazote, PORON, EVA, PE, and PU foams, all available in various densities, thicknesses, and sheet sizes. Each material is selected and tested to ensure consistency, durability, and clinical performance. 

Why foam selection matters in O&P

Foam materials help spread load evenly across a contact surface, reducing localised pressure that can lead to discomfort, tissue damage, or ulceration. This is especially important in orthoses for patients with diabetes, where poor circulation and neuropathy increases the risk of pressure sores. 

Foams like Plastazote, which conform to the foot shape under heat and pressure, and ideal for pressure redistribution due to their ability to mould precisely to the contours of the foot. 

In both prosthetic and orthotic manufacture, shock-absorbing foams reduce impact forces transmitted through the limb or foot during walking and standing This is particularly valuable for active individuals or those with joint pains, arthritis, or limb sensitivity. Materials such as PORON and PU foams are known for their excellent energy-absorbing properties, making them common choices for prosthetic liners, heel inserts, and orthoses.

Foam type affects how the skin interacts with the device. If it is the wrong foam, too rough, too hot, or too abrasive, this can lead to friction, heat build-up and eventual skin breakdown. For patients with fragile or at-risk skin, such as those with neuropathy or vascular disease, soft, non-irritating, and breathable foams are essential. Closed-cell foams like Plastazote offer a hypoallergenic surface that’s smooth and gentle on sensitive skin, while resisting moisture or bacterial build-up, a key factor in maintaining hygiene and skin health.

Different foam types also serve distinct purposes based on the application. Prosthetic liners require materials that offer cushioning and durability under dynamic loads, with the ability to conform to the residual limb while resisting compression over time, foams like PORON or soft PE are ideal for reducing shear forces and enhancing comfort inside the socket. 

The orthotic footbed, on the other hand, must strike a balance between support and flexibility, often using a layered approach with a soft layer for pressure relief, and a firmer base like EVA to provide structural integrity. These materials must also withstand heat moulding and repetitive stress from walking. 

Lastly, interface materials between rigid orthotic shells and the body, such as in AFO’s, need to offer localised cushioning without compromising shape or absorbing moisture, making PU and EVA foams popular choices due to their resilience, comfort and mouldability,

Overview of common foam types

Plastazote is a closed-cell, cross-linked polyethylene foam widely recognised for its skin-friendly properties and exceptional mouldability. Available in a range of densities, this foam is heat-formable, lightweight, and ideal for direct contact with the skin. It’s particularly suitable for diabetic orthoses and other applications requiring pressure redistribution, as it moulds closely the body, minimising shear and friction. 

Algeos offers Plastazote in multiple colours and sheet sizes, allowing clinicians to customisable devices both functionally and aesthetically.

is a high-performance, closed-cell foam made from ethylene-vinyl acetate (EVA)copolymers, known for its superior elasticity and durability compared to the standard plastazote. It combines the softness of low-density foams with greater tear resistance and tensile strength, making it ideal for more active users or devices that undergo frequent stress. 

Commonly used in orthotic top covers, padding for splints, and custom bracing, Evazote offers a balance of comfort, resilience, and long-term wear resistance.

PORON Medical is an open-cell polyurethane foam that offers excellent shock absorption, energy return, and moisture management. Unlike closed-cell foams, PORON breathes, reducing the risk of heat build-up and moisture accumulation, which is crucial in applications involving skin contact. It maintains consistent cushioning performance over time and resists compression set, making it ideal for prosthetic liners, foot orthoses, and impact-prone areas. 

Algeos supplies PORON in various thicknesses and formulations, tailored for clinical therapeutic use.

EVA (Ethylene Vinyl Acetate) foam is a versatile, closed-cell material available in a wide range of densities from soft cushioning layers to rigid structural components. Its commonly used in orthotic base layers, footbed and shell construction due to its ability to be heat-moulded, ground, and shaped with ease. 

EVA provides a good balance of flexibility and support, and its shock-absorbing properties make it suitable for both paediatric and adult applications. Algeos offers multiple grades and colours, enabling clinicians to layer and tailor devices based on patient-specific needs. 

Choosing the right foam for orthotic and prosthetic applications is far more than technical detail, it’s a clinical decision that can significantly influence patient comfort, device performance, and long-term health outcomes. 

With such a wide variety of materials available, each offering unique properties in terms of density, resilience, mouldability, and skin compatibility, it’s essential to tailor your foam choices to the individual needs of each patient. Combining different foam types, such as using a soft top layer with a supportive base, can often deliver the best results in terms of both comfort and functionality.

Whether you’re addressing complex conditions like diabetes managing residual limb care, or creating durable orthotic supports, the right materials make all the difference.