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Plastazote Sheets - Buy Online UK - Multiple Densities & Colours

Plastazote sheets are a high-performance solution for cushioning, protection, insulation and specialist fabrication. This closed-cell, cross-linked polyethylene foam is lightweight, durable and easy to work with, making it a popular choice across medical, orthotic, automotive, aerospace and industrial applications.

Available in a range of densities, thicknesses and colours, these foam sheets can be selected to suit a wide variety of technical and commercial uses.

Shop Plastazote foam sheets for dependable, versatile material performance tailored to your application.

Custom or bespoke orders on enquiry.

Plastazote Foam Sheets

Sold: Sheet
Incl. VAT Exl. VAT
£5.35 £4.46

A Versatile Material for Orthotics, Footwear, Gaskets, Medical Protection 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 for use 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

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.

Frequently Asked Questions

Why is Plastazote used in orthotics and prosthetics?

Its closed-cell structure makes it waterproof, hygienic, and resistant to sweat or moisture absorption. It provides excellent cushioning, shock absorption and pressure distribution - which helps reduce pressure points and improve patient comfort.

Is Plastazote safe for sensitive skin or diabetic patients?

Yes. Plastazote is hypoallergenic, latex-free, non-toxic and suitable for long-term skin contact. Its smooth surface and pressure-reducing properties make it ideal for diabetic foot care and sensitive skin applications.

What densities and thicknesses are available?

Plastazote sheets are available in a wide range of densities from very soft to firm grades. Thickness options vary depending on the intended use, allowing clinicians and technicians to choose the most appropriate combination for insoles, padding, or device linings.

Can Plastazote be heat-moulded?

Yes. Plastazote can be heat-moulded at controlled temperatures to create customised shapes. This makes it ideal for bespoke orthoses, custom insoles, prosthetic liners, and tailored padding solutions.

Is Plastazote waterproof and easy to clean?

Because it’s closed-cell, Plastazote does not absorb water or fluids. It can be wiped clean, disinfected and used in environments where hygiene and moisture resistance are essential.

What are some common applications beyond foot care?

Plastazote is also used for protective packaging, sports padding, impact protection, medical supports, seating systems, cushioning, buoyancy aids, and custom inserts in many industries including healthcare, aerospace, and manufacturing.

Does Algeos offer custom cutting or lamination?

Yes. Algeos can supply Plastazote sheets that are cut, split, laminated or customised to specific dimensions and requirements for orthotic, prosthetic and medical manufacturing applications.

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Category Manager

Marc Cameron

Materials and product development specialist with over 25 years of experience in health-related materials, orthotic therapy, and medical product innovation. Deep knowledge of foams, polymers, composites, adhesives and functional materials used across orthotic, rehabilitation, and healthcare applications. Writes for clinicians, techs and educated consumers seeking clear, evidence-informed guidance without the marketing fluff.