Foam Spotlight: Everything to Know About Polypropylene Foam

Polypropylene foam (PP) is a foam material with a wide range of applications. It’s known in many industries for its unique properties, versatility, and the benefits it can provide. Is it right for your application? This brief overview will introduce you to the material, what it’s known for, and whether it can be used with your products.  

Discover the composition, advantages, disadvantages, and common applications of polypropylene foam. 

What is Polypropylene Foam?

Polypropylene is a thermoplastic polymer known for its exceptional chemical and thermal resistance. The closed-cell structure of polypropylene foam is derived through a polymerization process involving propylene monomers. This results in a material with distinct properties, making it highly sought after for various applications. 

Polypropylene Foam is composed of polymers derived from propylene monomers, creating a thermoplastic structure that is tough and resilient, but also lightweight. 

Its closed-cell nature enhances its resistance to water and moisture, and the foam is also resistant to many chemicals, solvents, and greases. Known for its low density, polypropylene foam provides a lightweight solution with an excellent strength-to-weight ratio. 

Polypropylene foam can also be obtained in a beaded form known as EPP Foam (Expanded Polypropylene).    

The Benefits of Polypropylene Foam

Polypropylene Foam offers a multitude of benefits, making it a preferred choice in various industries. The primary reasons to use polypropylene foam include: 

  • Compression properties: strength to weight ratio and resistance to creep/set are typically very good 
  • Chemical resistance: resistant to a wide range of chemicals, making it ideal for applications requiring protection against corrosive substances. 
  • Water and moisture resistance: the closed-cell structure ensures resistance to water and moisture, enhancing its durability. 
  • Lightweight and buoyant: the low density of polypropylene foam makes it remarkably lightweight and buoyant, which is why it’s suitable for marine applications and environments. 
  • Versatility: polypropylene foam is easily customizable, allowing for versatility in fabrication and use across diverse industries. 

The Drawbacks of Polypropylene Foam

While polypropylene foam offers numerous advantages, there are some scenarios where another type of foam may be the better choice. Polypropylene foam is not ideal for applications that need strong: 

  • UV resistance: the foam lacks resistance to prolonged exposure to ultraviolet (UV) radiation, which can impact its longevity in outdoor applications. 
  • Thermal resistance: compared to some other foams, polypropylene foam may have limitations in high-temperature applications. 

The Most Common Applications of Polypropylene Foam

Polypropylene foam finds application across various industries due to its unique properties: 

  • Packaging: especially for items sensitive to moisture and chemicals. 
  • Floater pallets, crate blocking/bracing 
  • Automotive: for components requiring lightweight yet durable solutions. 
  • Marine: for buoyancy and insulation. 
  • Construction: for insulation and as a lightweight building material. 

Is Polypropylene Foam Right for Your Application?

Determining whether Polypropylene Foam is the right fit for your application depends on specific requirements. Consider its benefits, drawbacks, and the unique demands of your project to make an informed decision. Understanding its properties and applications can help you leverage its strengths for optimal results in your projects. 


Interested in using polypropylene foam in your application? Get in touch with our team today. We can help you make the right choice.