Materials · Cross-Linked Polyethylene

XLPE Foam — Cross-Linked Polyethylene

Cross-linked polyethylene foam (XLPE) is a premium closed-cell material offering superior resistance to water, chemicals, and impact. Available in chemically and physically expanded forms across a wide range of densities and colours ideal for protective packaging, moulded components, and precision die-cut applications.

Closed-Cell Water Resistant Chemically & Physically Expanded 20+ Colours Custom Die-Cut & Moulded

Closed-Cell

Cell Structure

28–240

kg/m³ Density Range

-70C

to +100°C Service Temp

20+

Available Colours

Material Overview

What Makes XLPE Foam Different?

Unlike standard polyethylene foam, XLPE undergoes a cross-linking process either chemical or physical (irradiation) that transforms its molecular structure into a fine, uniform closed-cell matrix. The result is a stronger, more resilient material with consistently superior performance across a wide range of conditions. kristoFOAM offers both chemically expanded and Zotefoams physically expanded XLPE in a broad selection of colours and densities.

Superior Water Resistance

XLPE's closed-cell structure prevents water absorption, making it ideal for marine, outdoor, and moisture-sensitive packaging applications.

Fine, Uniform Cell Structure

The cross-linking process produces a micro-cellular appearance with consistent cell size delivering uniform cushioning performance and a smooth, aesthetic surface finish.

Wide Density Range

Available from ultra-light 2 kg/m³ to high-density 220 kg/m³ grades, XLPE can be specified for anything from delicate electronics packaging to heavy-duty load support.

Chemical & UV Resistance

Excellent resistance to oils, solvents, acids, and UV exposure makes XLPE suitable for industrial, automotive, and outdoor environments.

Technical Data

XLPE Foam Technical Specifications

VIEW TECHNICAL SHEET

Key material properties for cross-linked polyethylene foam. Exact values vary by grade, density, and manufacturer contact us for specific data sheets.

Cell Structure

Closed-Cell

Micro-cellular, uniform

Density Range

2–220 kg/m³

Multiple grades available

Service Temp.

–60° to +90°C

Grade dependent

Water Absorption

< 0.1%

By volume (ASTM D3575)

Expansion Type

Chemical & Physical

Colours

20+

Custom colours available

Available Forms

Sheet, Roll, Bun

Die-cut & moulded parts

Recyclable

Yes

Polyethylene recyclable stream

Common Uses

Where XLPE Foam Is Used

XLPE foam's closed-cell structure, water resistance, and wide density range make it the material of choice across a broad range of industries and applications.

Custom die-cut foam inserts for cases, trays, and cartons protecting electronics, instruments, and high-value components during shipping and storage.

Precision-moulded XLPE parts for automotive interiors, military gear, sports helmets, and consumer products requiring complex 3D shapes.

Low-density XLPE provides excellent buoyancy for life jackets, paddleboards, boat padding, and marine safety equipment.

Impact-absorbing XLPE padding used in helmets, body armour, yoga mats, gymnastics equipment, and protective sporting gear.

Closed-cell structure provides effective thermal insulation for pipes, HVAC systems, and cold storage panels with minimal moisture absorption.

Door panel inserts, headliner backing, NVH dampening pads, and under-hood insulation in light and heavy vehicle applications.

Product Gallery

XLPE Foam Products & Forms

XLPE foam is available in bun stock, sheets, rolls, and custom die-cut or moulded components in a wide range of colours, densities, and thicknesses to suit any application.