What is EPP?

Expanded Polypropylene (EPP) Foam is a unique material.

It is made in a multi-step process that begins by combining polypropylene resin with special additives, then processing the material to form individual plastic beads, which may range from 4mm to 6mm in diameter, depending on the grade. These individual beads are then injected into a steam chest mold, where the individual beads are fused together under steam heat and pressure.

The resulting moulded product is a remarkably durable, yet resilient solid material.

EPP foam is flexible (semi-rigid) and light in weight, and was originally designed for automotive energy management applications, and for computer packaging as a cushioning material. EPP absorbs energy over and over again without denting or breaking, which makes it an ideal material for hobbiest applications like radio controlled aircraft.

EPP is a closed cell foam. It is effective across a wide temperature range (-40° to +100°) and has high chemical resistance to petrol, acetones and most chemicals found around the shop or home. EPP is virtually unaffected by exposure to water, and is extremely buoyant, which makes it useful in marine applications.

EPP is environmentally friendly. It can be recycled easily, and no toxic chemicals are used in its manufacture.

While EPP closely resembles expanded polystyrene, the white foam sometimes used in packaging, there is no comparison in structural strength. EPP is used for a range of applications in the automotive industry for components such as energy absorbers in bumpers, side impact protection, column covers, knee protection, seating structures, consoles, tool kits, parcel shelves and more.