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Plastazote Foam

Plastazote foam is a closed-cell, cross-linked polythene foam that is known for its high performance and versatility. The foam is commonly used in a variety of applications, including cushioning, insulation, and packaging, due to its ability to withstand extreme temperatures, high compression, and repeated impacts.

Plastazote is known for its low water absorption, making it well-suited for use in damp or humid environments. It is often used in the automotive, aerospace, and medical industries, as well as in consumer products.

Plastazote foams are available in a range of densities and colours and can be customised to meet the specific needs of different applications.

Plastazote Foam

Plastazote Foam from Algeos

A Versatile Material for Orthotics, Footwear, Gaskets and Sportswear

Plastazote stands out for its remarkable properties and versatility. This closed-cell, cross-linked polyethylene foam is highly regarded in the medical field, as well as in sports equipment, protective packaging, gaskets and many other industries.

What is Plastazote Foam?

Plastazote is a closed-cell foam made from polyethylene, known for its lightweight, flexibility and excellent cushioning properties. It is produced through a process of cross-linking and expansion, which gives it a uniform structure with evenly distributed cells. This structure not only makes Plastazote lightweight but also imparts it with excellent thermal insulation and impact resistance qualities.

One of the standout features of Plastazote is its hypoallergenic nature, making it a popular choice in medical applications where contact with the skin is involved. Its non-toxic and inert properties ensure that it doesn’t cause allergic reactions or irritation making it safe for long-term use.

Plastazote in Orthotic Insoles and Footwear

Plastazote has long been a favourite material for orthotic insoles and footwear particularly in the field of podiatry. Its unique combination of comfort, support and safety makes it an ideal choice for individuals who require customised foot care solutions. Here are some of the key reasons why Plastazote is so widely used in this area:

  • Custom Moulding: One of the primary benefits of Plastazote is its ability to be heat-moulded. This allows podiatrists and orthotists to create custom-moulded insoles that conform precisely to the shape of an individual’s foot, providing optimal support and pressure distribution. This customisation is especially beneficial for patients with diabetes or other conditions that affect foot health.
  • Cushioning and Pressure Relief: Plastazote’s soft, cushioning nature helps to distribute weight evenly across the foot, reducing pressure points that can lead to pain and discomfort. This makes it an excellent material for orthotic insoles designed to alleviate conditions such as plantar fasciitis, metatarsalgia, and other foot-related issues.
  • Durability and Longevity: While Plastazote is soft and comfortable - it is also durable enough to withstand the daily wear and tear associated with walking and standing. This durability ensures that orthotic insoles made from Plastazote remain effective over time providing lasting comfort and support.
  • Hypoallergenic and Skin-Friendly: For patients with sensitive skin or allergies - Plastazote is an ideal choice. Its hypoallergenic properties mean it is unlikely to cause irritation or allergic reactions, making it suitable for direct contact with the skin in insoles and other footcare products.

Beyond Footwear: Other Uses of Plastazote Foams

While Plastazote is widely used in orthotic insoles and footwear its applications extend far beyond the realm of footcare. Thanks to its versatility Plastazote is employed in various industries for different purposes. Here are some broader uses of this remarkable material.

Applications of Plastazote

Industry Application Benefits
Medical Orthotic Insoles Custom moulding, cushioning, pressure relief, hypoallergenic
Medical Orthopaedic Supports and Splints Custom shaping, support, protection
Medical Prosthetics Cushioning, comfort, durability
Protective Packaging Electronics and Sensitive Equipment Impact and vibration protection, lightweight
Protective Packaging Custom Foam Inserts Secure positioning, protection from damage
Sports and Leisure Sports Padding and Protection Impact absorption, lightweight
Sports and Leisure Water Sports Equipment Buoyancy, water resistance


Whether you’re in the field of podiatry, orthopaedics, sports or industrial manufacturing, Plastazote’s wide-ranging applications can help you meet the needs of your clients and end-users. As a material that has proven its worth across diverse applications Plastazote is undoubtedly a key component in the design and production of products that require both safety and comfort.

With Plastazote, you can be confident that you’re choosing a material that not only delivers on performance but also stands the test of time. Whether it’s cushioning a patient’s foot or protecting delicate equipment, Plastazote’s versatility ensures it remains a top choice across industries.

Algeos can laminate, split sheets and cut sheets to your dimensions. We can also provide shape cutting services for larger orders and even pack to your requirements. If you are interested in these services, please get in touch with your custom requirements.