Plastazote Foam Sheets

Plastazote Foam Sheets

Plastazote is the most common closed-cell, polyethylene foam used in the foot orthotic industry. It will adhere to most materials, it is readily washable, discourages bacteria growth and has good thermal properties.

Plastazote foams have widespread uses in orthotics, prosthetic linings and foot care appliances. A thermoplastic polyethylene foam, Plastazote is easily heat moulded (85-140°C) and will adhere to most materials.

Its unique cross linked construction and non toxicity have established Plastazote as the standard for orthotic linings. It is readily washable, discourages bacteria growth and has good thermal properties. Medical application areas include: orthotics, splinting, seating, collars, prosthetic padding & protective equipment.

Bespoke service available on request: We can perforate, add adhesive backing, offer a cutting service and lamination service that allows us to bond any 2-3 materials together. 

Plastazote Foam Sheet Characteristics

    1.    Lightweight: Being made from polyethylene - Plastazote is extremely light, making it easy to handle and work with.
    2.    Non-toxic and Safe: It is non-toxic, hypoallergenic and doesn’t allow microbial growth making it safe for medical and personal use.
    3.    Versatile: Available in various densities, thicknesses and colours catering to different needs and applications.
    4.    Durable and Resilient: It has excellent resistance to water, chemicals and physical impact - ensuring long-lasting performance.

Plastazote Grades:

1. Understanding Plastazote Foams

Plastazote foams are closed-cell, cross-linked polyethylene foams known for their exceptional properties, including durability, flexibility, chemical resistance and cushioning abilities. They are commonly used in various industries due to their versatility.

2. Applications

    •    Orthotics and Prosthetics: Plastazote’s moldability makes it ideal for orthotic insoles, prosthetic liners and padding for braces.
    •    Packaging and Protection: Used for protective packaging in industries like electronics, healthcare and automotive due to its shock absorption/cushioning properties.
    •    Sports and Leisure: Employed in sports equipment, helmets, padding and flotation devices due to its impact resistance and buoyancy.
    •    Medical and Healthcare: Utilised in splints, cushioning materials for medical devices and wheelchair seating - due to its hypoallergenic and non-toxic nature.
    •    Specialised Industrial Applications: Includes gaskets, seals, insulation and vibration dampening due to its resistance to chemicals and temperature.

3. Working with Plastazote Foams

    •    Cutting and Shaping: Can be easily cut with sharp knives, scissors, or die-cutting machines. Heat shaping using hot air or water allows customisation .
    •    Bonding: Bonds well with adhesives suitable for polyethylene-based materials. Solvent bonding or heat welding methods can also be used for joining pieces.
    •    Molding: Heating Plastazote allows it to be shaped into desired forms. Use caution to avoid overheating, which can damage the material.
    •    Finishing: Surface treatment - such as painting or laminating, can enhance appearance and functionality.
    •    Care and Maintenance: Plastazote foams are durable but should be protected from excessive heat, prolonged sunlight exposure and harsh chemicals.

4. Safety Considerations

    •    Ventilation: Adequate ventilation is necessary when heat shaping or bonding to avoid inhalation of fumes.
    •    Protective Gear: Wear appropriate gloves and eye protection when working with cutting tools or chemicals.

5. Selecting the Right Plastazote Foam

Consider factors such as density, color, thickness, and specific properties required for the intended application. Plastazote is available in various grades and densities to suit different needs.

6. Storage

Store Plastazote foams in a dry, cool area away from direct sunlight and extreme temperatures to maintain their properties.

7. Environmental Considerations

Plastazote foams are recyclable. Check with local recycling facilities for guidance on proper disposal and recycling methods.

This guide provides an overview of the versatile uses and handling of Plastazote foams, but always refer to the manufacturer’s instructions and safety data sheets for specific details and recommendations regarding their products.

What Experts Say

According to leading materials scientists and industry experts, Plastazote is highly regarded for its balance of performance, safety and versatility. Its widespread adoption across diverse fields is a testament to its efficacy and reliability.

For orthotists, prosthetists, podiatrists and other healthcare professionals, Plastazote’s unique properties can greatly enhance medical devices, offering comfort, protection and custom solutions tailored to individual needs.