Plastazote is a closed-cell, crosslinked polyethylene (XLPE) foam known for its exceptional purity, cushioning, and versatility. Manufactured by Zotefoams, it is widely used in medical devices, orthotics, protective packaging, and engineering solutions requiring clean, consistent materials.
What is Plastazote?
Plastazote is made from low-density polyethylene (LDPE) and undergoes a unique crosslinking process using high-energy radiation and pure nitrogen gas. This transforms the plastic into a durable, flexible foam with closed cells—completely sealed off from moisture, air, and chemicals.
Key characteristics include:
- Non-toxic, latex-free and hypoallergenic
- Waterproof and chemically inert
- Softens with heat (doesn’t melt or drip)
- No residual solvents or volatiles
- Density range from 15 to 115 kg/m³, from soft to firm grades
Why Plastazote Excels
1. Biocompatibility and Hygiene – Plastazote is non-toxic, hypoallergenic, latex-free, and inherently pure-making it ideal for medica use. It compiles with FDA and ISO standard for skin contact and is often the material of choice in orthotics, prosthetics, and surgical packaging.
2. Superior cushioning and shock absorption – the foam’s structure is designed to absorb energy without collapsing or deforming. It’s lightweight but tough, making it a go-to material for sports padding, braces, and instrument cases.
3. Moisture and chemical resistance – the closed-cell design makes Plastazote imperable to water, oils, and most chemicals. It won’t degrade in wet conditions or support microbial growth, vital for both clinical and industrial environments.
4. Thermoformability and customisation – plastazote softens at ~135 °C, allowing it to be easily thermoformed into custom shapes. It can also be:
- Cut with knives, routers, or CNC machines
- Laminated or bonded with special adhesives
- Produced in multiple colours and densities
This makes it ideal for custom insoles, braces, packaging inserts, and much more.
Properties and Advantages
Plastazote combines exceptional lightness with reliable cushioning and outstanding chemical stability. Renowned for its “lightweight durability” and “superior shock absorption,” its closed-cell structure keeps water, oils, and most chemicals at bay — ensuring long-term integrity in even demanding environments.
Its thermal insulation properties are equally impressive, with low thermal conductivity and a consistent hardness across varied temperatures.
Zotefoams highlights its material purity: Plastazote is latex-free, non-toxic, and hypoallergenic — essential features for medical-grade performance. Many variants are ISO and FDA compliant, safe for direct skin contact, and free from plasticisers or residual monomers.
Every roll reflects Plastazote’s engineered consistency — with uniform cell structures and density profiles that provide dependable cushioning and predictable results.
Its buoyancy and flexibility make it ideal for impact protection — whether used in medical devices or sports equipment like helmets.
Crucially, Plastazote retains shape under sustained pressure, unlike open-cell foams prone to compression set and creep.
PottertonPacs also notes Plastazote’s “waterproof, long-lasting” build and “excellent chemical resistance.” Its transparency to X-rays, CT scans, and MRIs makes it particularly suited to orthotic and medical imaging applications.
Key Benefits of Plastazote Sheets:
- Biocompatible – Hypoallergenic, non-toxic and safe for direct contact.
- Durable Cushioning – High impact resistance with low weight.
- Easy to Fabricate – Cut, rout, glue or thermoform using common tools.
- Thermally Stable – Resists deformation across wide temperatures.
- Sealed Against Moisture & Chemicals – Doesn’t rot or support microbial growth.
- Tailorable – Offered in multiple densities, colours and functional grades (e.g. flame-retardant or conductive).
This unique blend of purity, performance and reliability makes Plastazote an ideal choice in applications demanding hygiene, safety and precision.
Disadvantages and Limitations
While Plastazote delivers outstanding performance across a wide range of applications, there are a few considerations to keep in mind.
- Higher Cost: As a precision-engineered foam, Plastazote is more expensive than basic commodity foams due to its specialised manufacturing process.
- Limited Recyclability: Crosslinked polyethylene foams don’t remelt cleanly, making traditional recycling difficult. Disposal options typically include incineration or mechanical processing. Being petroleum-derived, Plastazote is not biodegradable and requires responsible handling.
- Heat Sensitivity: The foam softens above approximately 70 °C and may shrink when held near its softening point (105–115 °C) over time. This limits its suitability for autoclaving or hot-water sterilisation.
- UV Vulnerability: Extended exposure to direct sunlight or heat sources can cause warping and shrinkage. Products should be stored away from harsh light or wrapped in opaque material to preserve integrity.
- Static Build-up: Large sheets may accumulate static charge when cut, a common trait among insulating materials. For environments where this is a concern, conductive or dissipative variants are available.
- Initial Odour: Like many foams, freshly crosslinked Plastazote may carry a mild chemical scent. This typically fades quickly with exposure to air and does not impact the foam’s safety or inertness.
Working with Plastazote Sheets
Working with Plastazote is straightforward, but following a few key guidelines can ensure clean finishes, precise shapes, and long-lasting performance.
Cutting and Machining
Plastazote sheets can be easily cut using sharp craft knives or processed with saws, routers, and waterjet machines. Always use clean, sharp tools to avoid tearing or fraying the material. Coarser tools, such as bandsaws and CNC routers, are especially effective. Because fine foam dust can be produced during machining, light dust extraction is recommended.
For smooth edges, sanding or filing is effective. Keep in mind that the foam may compress slightly under pressure, so using backing materials or making multiple shallow passes can help maintain accuracy.
Thermoforming
To mold Plastazote into 3D shapes, apply heat. Zotefoams recommends heating LDPE-based Plastazote in a fan-assisted oven at approximately 135–140 °C. This allows the foam to soften evenly without degrading.
For vacuum or pressure forming, plastic or wooden molds can be used. Avoid exceeding 145 °C, as temperatures beyond this point can cause the foam to shrink excessively.
In orthotic applications, “direct-to-body” molding is commonly used. A preheated sheet is placed on a non-stick surface with thermal protection, and the patient’s foot is gently pressed into the foam to capture an exact impression. The foam cools quickly, retaining the molded shape.
Bonding and Laminating
Working with Plastazote is straightforward, but following a few key guidelines can ensure clean finishes, precise shapes, and long-lasting performance.
Cutting and Machining
Plastazote sheets can be easily cut using sharp craft knives or processed with saws, routers, and waterjet machines. Always use clean, sharp tools to avoid tearing or fraying the material. Coarser tools, such as bandsaws and CNC routers, are especially effective. Because fine foam dust can be produced during machining, light dust extraction is recommended.
For smooth edges, sanding or filing is effective. Keep in mind that the foam may compress slightly under pressure, so using backing materials or making multiple shallow passes can help maintain accuracy.
Thermoforming
To mold Plastazote into 3D shapes, apply heat. Zotefoams recommends heating LDPE-based Plastazote in a fan-assisted oven at approximately 135–140 °C. This allows the foam to soften evenly without degrading.
For vacuum or pressure forming, plastic or wooden molds can be used. Avoid exceeding 145 °C, as temperatures beyond this point can cause the foam to shrink excessively.
In orthotic applications, “direct-to-body” molding is commonly used. A preheated sheet is placed on a non-stick surface with thermal protection, and the patient’s foot is gently pressed into the foam to capture an exact impression. The foam cools quickly, retaining the molded shape.
Bonding and Laminating
Due to its chemical inertness, Plastazote does not adhere well with standard glues. Instead, use specialized contact adhesives (such as 3M Super 77 spray) or apply heat welding techniques for strong bonds.
Hot-air welding can be used to fuse sheets together at the edges. For gluing, prepare the bonding surface by cleaning with alcohol and lightly roughening it to improve adhesion. Always test the adhesive on a small sample first. For lighter bonding needs, PE-compatible double-sided tape is another option.
For large projects or multi-layered assemblies, laminating services are available through suppliers like Algeos.
Static and ESD Considerations
When cutting large Plastazote sheets, static electricity may build up, resulting in occasional sparks. While harmless to people, this can pose a risk for sensitive components. If electrostatic discharge (ESD) is a concern, consider using antistatic-grade Plastazote or maintaining moderate humidity levels in the workspace.
To further reduce static, ground your work surface and yourself using a wrist strap. Conductive and dissipative variants of the foam are also available from Zotefoams for ESD-sensitive environments.
Storage and Handling Tips
To maintain product quality, store Plastazote sheets flat and away from direct sunlight or heat sources. UV exposure can cause yellowing, warping, or degradation over time. Avoid wrapping sheets in clear plastic if exposed to sunlight, as this can create a greenhouse effect that may shrink or distort the foam.
If sheets have been stored in a cold environment, allow them to return to room temperature before cutting or heating. A 24-hour acclimation period is recommended to avoid thermal distortion during fabrication.
Because Plastazote can attract dust through static buildup, keep unused sheets covered or bagged when cleanliness is important.
By following these fabrication and handling guidelines, users can take full advantage of Plastazote’s versatility. Its ease of cutting, forming, and bonding—combined with its chemical purity and skin-safe properties—makes it an outstanding choice for custom medical, engineering, and packaging applications. Proper preparation ensures consistent performance and maximizes the foam’s potential in every use case.
