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Foam Materials

Foam Sheets

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Foam Materials

Foam Materials

Innovation in material sciences has brought forth a multitude of options catering to diverse industrial needs, and at Algeos, we pride ourselves on offering a spectrum of high-quality foam materials.

Among our prominent offerings are Plastazote foam, Poron urethanes and EVA foam - each distinctive in composition and engineered with unique properties that cater to a wide array of applications.

From exceptional shock absorption to unparalleled flexibility, these foam materials stand as pillars in various industries, providing unmatched performance and reliability.

Foam Sheets for Orthotics, Footwear, Padding and Practical Workshop Use

Foam sheets are used across orthotic manufacture, footwear adaptation, cushioning, padding, lining and general workshop fabrication. The key is choosing the right foam for the job. Use softer grades for comfort and support. Use firmer grades for structure and control.

Use specialist materials when shock absorption, skin contact, or moisture resistance matters most.

At Algeos you can browse the main foam sheets range, compare EVA foam sheets, explore Poron memory foams, and review Plastazote foam for more specialised clinical and manufacturing applications.

Read the foam selection guide

Good foam selection saves time later. The right thickness, density, and surface material can improve comfort. They can reduce pressure points, support accurate fabrication, and give a cleaner finish.

What are foam sheets?

Foam sheets are flat materials used as build-up, cushioning, lining, posting, padding or interface layers. In orthotics and footwear work they can be cut, heat-shaped, bonded, skived, layered or ground depending on the foam type and the result required.

Algeos supplies 3 types: EVA for versatile fabrication and structure, Poron for high-performance cushioning and resilience, and Plastazote for lightweight closed-cell cushioning, skin contact and pressure redistribution.

Why people use our foams

To add cushioning, comfort or shock attenuation underfoot
To create supportive orthotic builds with specific density choices
To line devices where skin contact and hygiene matter
To modify footwear quickly and neatly in the workshop
To laminate layers for mixed performance rather than one single material
To support condition-led pressure redistribution in sensitive feet

Algeos foam types

Characteristic	EVA Foam	Poron Foam	Plastazote Foam
Cell Structure	Closed‑cell, fine uniform structure	Micro/ open‑cell polyurethane	Closed‑cell, cross‑linked PE
Density	20 - 280 kg/m³ (typical range 20 - 150 kg/m³)	Moderate to high - varied by grade	Available in various densities (e.g. LD60, HD115)
Hardness	15 - 80 Shore C depending on density	Customisable firmness - designed for compression resistance	Medium firmness - varies by grade
Compression & Recovery	Low compression set - resilient rebound	Exceptional compression‑set resistance - retains shape	Recovers well from impacts - maintains cushioning
Impact Absorption	Good shock absorption, buoyancy	Superior energy absorption, used in electronics/seals	Excellent impact resistance, surface protection
Water Resistance	Low water absorption, buoyant	Good resistance, chemicals tolerable	Water‑repellent, closed‑cell PE resists moisture
Chemical Resistance	Resistant to oils, fuels, solvents, UV	Excellent solvent/chemical resistance	Outstanding resistance to chemicals, acids, alkalis
Temperature & UV Stability	Good UV resistance, tolerates wide temp range	Stable across typical application temperatures	Excellent thermal insulation, UV stable, temp resistant
Fabrication Ease	Easily cut, shaped, thermoformed, glued	Die‑cut, slit, laminated; clean fabrication	Easy to cut, shape, glue, non‑staining
Biocompatibility	Non‑toxic - used in orthotics & medical devices	Low outgassing - safe in electronics & medical gear	Non‑toxic, latex‑free, hypoallergenic
Typical Uses	Footwear insoles, crafts, mats, orthotics, sports gear	Cushioning for electronics, seals, footwear inserts	Orthotic liners, prosthetics, padding, arch supports

EVA foam sheets

Usually the starting point for device build, posting, structure and general workshop versatility. EVA is available in a broad spread of densities and thicknesses.

Low density A25, medium density A50, high density A65, AirLite super soft EVA and Algefoam soft and light EVA all serve different build goals.

Properties: EVA foam is flexible, cost-effective, resilient and easy to mold and shape. It offers good cushioning and is available in various densities and colours.

Applications: Widely used in custom orthotic devices, shoe midsoles and padding for sports equipment. Its versatility also extends to toys, automotive interiors and craft projects due to its ease of fabrication.

Poron sheets

Often chosen where long-term cushioning, impact reduction and recovery from repeated loading are priorities. Suitable for top covers, inserts and pressure-sensitive applications.

Explore the full Poron range or compare more specialist options such as Poron Fusion.

Properties: Made from microcellular polyurethane, Poron offers excellent shock absorption, energy return and long-lasting durability. It maintains performance over time without hardening or collapsing.

Applications: Frequently used in insoles for footwear, protective padding in sports gear and electronic device cushioning. It is particularly valued for its ability to absorb impact and reduce pressure points.

Plastazote and hybrid foams

Closed-cell Plastazote is useful where low water absorption, cleanability, softness and direct skin contact are important. Laminated or hybrid sheets can combine support and comfort in one build.

See Plastazote foam sheets and the wider hybrid foam sheets category.

Properties: Closed-cell, cross-linked polyethylene foam known for its lightweight, non-absorbent and highly conformable nature.

Applications: Ideal for orthotic linings, padding and cushioning in sports equipment, as well as protective packaging. Its hypoallergenic and non-toxic properties make it suitable for direct skin contact.

How to choose foam sheets

Start with the job the material needs to do

Ask whether the foam is providing structure, comfort, accommodation, lining, posting or impact reduction. The answer immediately narrows the choice.

Choose density before colour

For most orthotic and workshop tasks, density matters far more than appearance. Softer grades usually feel more accommodating, while firmer grades tend to hold shape better under load.

Check thickness and finishing needs

Thin sheets may suit top covers or interface layers. Thicker sheets may be better for build-ups, posting or larger modifications. Also check whether you need to grind, heat mould, laminate or bond the material.

Think about the user, not just the device

For active wearers, durability and resilience may lead the decision. For sensitive or high-risk feet, pressure redistribution, skin-friendliness and surface feel may be more important.

Use layered builds where needed

Many of the best outcomes come from combining materials rather than relying on one sheet alone. Browse hybrid foam options or combine EVA with softer top layers where clinically appropriate.

Helpful guides and advice

Choosing the right foams for orthotic and prosthetic production

A strong starting point for clinicians, technicians and workshop teams comparing performance and applications.

Guide to buying EVA foam sheets

Useful when you need clearer advice on density, thickness and general workshop selection.

How EVA foam is used in orthotic insoles

Explains where EVA sits in orthotic builds and why density choice changes performance.

Poron cushioning in footwear and orthotics

Helpful for buyers looking at premium shock attenuation and long-term cushioning.

Plastazote foam: chemistry, manufacturing and applications

Good background reading if you are comparing closed-cell materials and pressure care use.

Are memory foam shoe inserts the right choice?

A useful comparison piece when users are weighing soft comfort against more structured support.

Browse all Algeos product guides

Ideal if you are still narrowing the material route or comparing categories.

See finished orthotic insoles

Useful for customers moving from material selection into ready-made support options.

Popular brands, product families and solution types

Aortha EVA range

Broad coverage across densities and thicknesses for build, posting, lining and general workshop use.

Algefoam

Low density EVA commonly used where a softer, lighter finish is wanted.

Poron

For cushioning, recovery and pressure-sensitive top cover or lining applications.

Plastazote

Closed-cell option for pressure redistribution, hygiene-focused builds and sensitive-foot applications.

Popular options to compare

Aortha A25 low density EVA

Softer EVA for cushioning, accommodation and lighter-duty applications where conformability is helpful.

Aortha A50 medium density EVA

A widely used mid-point option for many orthotic and workshop jobs, balancing workability and support.

Aortha A65 high density EVA

Firmer sheet for builds that need more structural support and better resistance to compression.

AirLite super soft EVA

A soft, mouldable option often considered where comfort and finish are important.

Foam sheets FAQs

What is the difference between EVA, Poron and Plastazote foam sheets?

EVA is usually the most versatile workshop material for build and structure, Poron is often chosen for high-performance cushioning and recovery, and Plastazote is a closed-cell option used where softness, cleanability and pressure redistribution are important.

Which foam sheet is best for orthotic insoles?

There is no single best option. Many orthotic builds start with EVA for structure, then use softer cover or interface layers where extra comfort or accommodation is needed. This EVA guide is a helpful place to begin.

How do I choose the right density?

Lower densities usually feel softer and more accommodating. Higher densities tend to hold shape better and provide more control. Matching density to the intended load, footwear space and user need is usually more important than simply choosing the softest material.

Are foam sheets suitable for diabetic or sensitive feet?

They can be, but material selection needs care. Pressure redistribution, skin tolerance, interface quality and total device design all matter. For finished solutions, compare diabetic insoles and neuropathy support options.

Can foam sheets be laminated or combined?

Yes. Combining materials is common when you want structure from one layer and cushioning or surface comfort from another. The hybrid sheet range shows how mixed constructions can support different outcomes.

Is memory foam the same as Poron?

No. Memory foam and Poron are different material families with different performance characteristics. If you are comparing softer comfort products against more resilient technical cushioning, see this memory foam comparison article.

Can I use foam sheets outside podiatry and orthotics?

Yes. Depending on the material, foam sheets are also used in craft, cosplay, packaging, marine, matting, protective padding and general fabrication work. The main consideration is still choosing the correct material properties for the task.

References

These sources are useful for a broader background on pressure care, diabetic foot risk and material-related cushioning principles.

Writer: Marc Cameron - Product Director

EVA Foam

Poron Memory Foams

Plastazote Foam

Hybrid Cushioning Foam Sheets