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There are basically four different materials (polymers) and two main manufacturing techniques that are used to meet required specifications.
Foams can be either moulded or converted. Moulding demand more complicated tooling but is often an economically preferable choice for large quantities.
Polyethylene (PE or EPE) is the most widely used polymer that can be moulded as well as fabricated depending on the requirements. It is a moisture resistant and resilient packaging material with good multiple drop cushioning performances. One main feature with PE is the possibility to recycle it. Polypropylene (PP or EPP) is a moulded foam that just like polyethylene is a moisture resistant and resilient material with good multiple drop cushioning performances. Polystyrene (PS or EPS) is a moulded foam with good insulation capability and good first drop cushioning performance.
Polyurethane (PU) is commonly fabricated but can also be moulded. The material is recognised as mattress or furniture material and is suitable as cushioning for light weight products and as interior packaging in cases.
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