Plastazote Foam is the most widely used closed-cell, cross-linked polyethylene foam in the foot orthotic industry and beyond. Lightweight, non-toxic, and durable, Plastazote combines comfort, versatility and performance.

It adheres easily to most materials, is readily washable, discourages bacterial growth, and offers excellent thermal insulation - making it ideal for orthotics, prosthetics, gaskets and sportswear.

Why Choose Plastazote Foam?

Plastazote has become the industry standard for orthotic linings thanks to its unique construction and skin-safe properties. It’s a thermoplastic polyethylene foam that can be easily heat-moulded (85–140°C) to form precise, comfortable, and hygienic supports for a range of medical and technical applications.

Key Characteristics of Plastazote Foam Sheets

1. Lightweight: Made from polyethylene, Plastazote is extremely light, making it easy to handle, cut and fabricate.
2. Non-toxic and Safe: Hypoallergenic and antimicrobial, it discourages bacterial growth and is suitable for direct skin contact.
3. Versatile: Available in a wide variety of densities, thicknesses, and colours to meet clinical, industrial, and creative needs.
4. Durable and Resilient: Highly resistant to water, chemicals, and impact, ensuring long-lasting performance and shape retention.

Available Grades and Specifications

Medical and Industrial Uses

Plastazote foams have wide-ranging applications across multiple sectors thanks to their unique combination of softness, durability and safety.

• Orthotics and Prosthetics: Orthotic linings, prosthetic padding, insoles, and AFOs.
• Medical Supports: Splinting, collars, and seating for patient support and comfort.
• Protective Equipment: Helmets, braces, and cushioning components.
• Industrial Use: Gaskets, seals, insulation, and vibration dampening.
• Sports and Marine: Protective sports padding, buoyant supports, and floatation devices.
• Packaging: Shock-absorbing protection for electronics, aerospace, and automotive products.

Bespoke Services Available from Algeos

Algeos offers custom conversion services for Plastazote foam sheets to meet your exact project requirements:

• Perforation
• Adhesive backing application
• Precision cutting and trimming
• Lamination of up to three materials

These services ensure materials are supplied ready for use in orthotic labs, prosthetic workshops or manufacturing environments.

Application Guide for Plastazote Foam Sheets

1. Understanding Plastazote Foams

Plastazote is a closed-cell, cross-linked polyethylene foam recognised for flexibility, durability and chemical resistance. It provides cushioning and shock absorption while resisting moisture and wear, making it ideal for clinical and industrial environments.

2. Applications

• Orthotics and Prosthetics: Perfect for custom-moulded insoles, braces, and prosthetic liners.
• Packaging and Protection: Shock-absorbing foam for electronics, healthcare devices, and automotive components.
• Sports and Leisure: Used in protective padding, helmets, and flotation gear.
• Medical and Healthcare: Splints, seat cushioning, and hypoallergenic supports.
• Industrial and Construction: Gaskets, seals, insulation, and vibration control applications.

3. Working with Plastazote Foams

• Cutting and Shaping: Easily cut with knives, scissors, or die-cutting machines; can be heat-shaped with hot air or water.
• Bonding: Bonds well with polyethylene-based adhesives; heat welding or solvent bonding can be used for joint work.
• Moulding: Heat between 85–140°C to shape; avoid overheating to prevent cell collapse.
• Finishing: Can be painted, laminated, or surface-treated to enhance appearance and performance.
• Maintenance: Washable and chemical-resistant but should be stored away from harsh chemicals or prolonged UV exposure.

4. Safety Considerations

• Ventilation: Ensure proper airflow when heat-forming or bonding to avoid inhalation of fumes.
• Protective Gear: Always wear gloves and eye protection when cutting or using adhesives.

5. Selecting the Right Grade

Choose your Plastazote grade based on density, colour and hardness needed for your project. Softer grades (LD24–LD33) are used for cushioning and medical applications, while firmer grades (LD45–LD60) suit load-bearing or structural applications.

6. Storage

Store Plastazote sheets in a cool, dry location away from sunlight and extreme heat to maintain their properties and appearance.

7. Environmental Considerations

Plastazote foams are recyclable. Check with local recycling facilities for specific guidelines on polyethylene foam recycling and disposal.

Expert Insights

According to leading materials scientists and industry professionals, Plastazote is one of the most balanced foams available today, combining performance, safety and versatility.

Its widespread use across orthotic, prosthetic, and industrial applications demonstrates its long-term reliability and adaptability.

Dependable Performance Foams

Plastazote Foam Sheets are the trusted standard for orthotic linings, prosthetic padding, and precision industrial uses. With multiple densities and grades available, they provide the flexibility, comfort, and durability required for clinical and manufacturing environments.

Whether you’re developing custom foot orthotics, prosthetic liners, or engineered gaskets, Algeos Plastazote delivers dependable performance and professional results every time.