Profile Foam (Egg Box)

What is Egg Box Foam?

Egg box foam, also known as egg crate foam, is a specialised foam material designed for cushioning, shock absorption, insulation, and soundproofing. Its distinctive peak-and-valley structure, resembling an egg carton, helps distribute pressure evenly while using minimal material. This makes it a lightweight, cost-effective, and efficient solution for a variety of applications, including packaging, sound insulation, and protective cushioning.

How is Egg Box Foam Made?

Egg box foam can be manufactured using different methods, with extrusion being one of the most common techniques. Extruded egg box foam is created through a precise and controlled process that ensures uniform quality and performance.

The Extrusion Process:

Material Preparation – The base foam material, often polystyrene (XPS or EPS), is blended with additives, stabilisers, and blowing agents to achieve the desired properties such as density, flexibility, and fire resistance.
Extrusion – The prepared foam mixture is heated and forced through a mould (die) that shapes it into the characteristic egg box pattern. This step creates air pockets within the foam, enhancing its shock absorption and insulation properties.
Cooling & Solidification – As the foam exits the extruder, it cools and solidifies, forming a continuous sheet with the egg crate profile.
Cutting & Finishing – The foam is then cut into sheets, blocks, or rolls of varying thicknesses and densities, ready for custom applications. Additional surface treatments may be applied to improve durability, fire resistance, or aesthetic appeal.

Benefits of Extruded Egg Box Foam

✔ Consistent Quality – The controlled extrusion process ensures uniform thickness, density, and structure, crucial for reliable performance in cushioning and insulation.

✔ Customisable Density & Thickness – Foam can be tailored to meet specific application needs, from protective packaging to acoustic insulation.

✔ Lightweight & Cost-Effective – The low weight of egg box foam reduces shipping and handling costs, making it an economical choice for businesses.

✔ Superior Shock Absorption – The peak-and-valley design enhances impact resistance, reducing damage during transport, storage, and use.

✔ Excellent Thermal & Acoustic Insulation – Its structural composition makes it ideal for soundproofing and temperature regulation in various industries.

✔ Versatile Applications – Used in packaging, construction, automotive, and acoustic treatment, extruded egg box foam is widely applicable across multiple industries.

Common Applications of Egg Box Foam

Protective Packaging – Ensures safe transport of fragile electronics, medical devices, and delicate goods.
Soundproofing & Acoustic Treatment – Used in recording studios, theatres, and industrial settings to reduce noise levels.
Construction & Insulation – Provides thermal insulation in walls, ceilings, and HVAC systems.
Automotive Industry – Applied in vehicle interiors and components to enhance vibration dampening and insulation.
Mattresses & Cushions – Used in bedding and ergonomic support products for enhanced comfort.

Get High-Quality Egg Box Foam from Drayton Foam

Looking for durable and high-performance egg box foam for your business? Drayton Foam offers custom-cut, premium-quality foam solutions tailored to your needs.