This article will take an in-depth look at closed cell foam.
The article will bring more understanding on topics such as:
This introductory chapter delves into the definition of closed cell foam and its production process. You will also discover the techniques used for cutting closed cell foam and learn about the key factors to consider when choosing this material.
Closed cell foam is a specific type of foam characterized by tightly packed and enclosed "cells." Unlike open cell foam, like polyurethane which features interconnected open cells, closed cell foam's lack of interconnection results in small, tightly packed cells containing pockets of gas. This structure contributes to its durability, making it ideal for more rigorous applications.
Thanks to its sealed cellular structure, closed-cell foam does not allow the penetration of water or moisture, making it highly resistant to pressure. It possesses higher density and is available in various forms, from rigid polyethylene to softer styles like Flotex. This versatile material ensures enhanced stability and offers a secure seal. Moreover, closed-cell foams come in a range of colors and thicknesses, and their superior robustness generally sets them apart from other foam types in terms of stiffness.
The production of closed-cell foam involves a series of specific processes and materials:
Polyethylene Foam - This type of polyethylene closed cell foam resists water absorption and stains. It's ideal for a broad spectrum of uses, offering excellent sound dampening, buoyancy, and shock absorption qualities, making it suitable for everything from packaging to arts and crafts.
Polyethylene Rolls – Available in rolls, this closed-cell foam suits a variety of sectors, including automotive, healthcare, and sports and recreational applications.
Cross-Linked Polyethylene – Offered in thicknesses between 0.063 and 0.700 inches with densities varying from 2 to 20 lb/cubic foot, this foam is available in rolls or buns that you can cut to any thickness. Its versatility and resistance to mildew, stains, and water make it an excellent option for packaging, flotation devices, construction, and industrial use. The durability and visual appeal of cross-linked polyethylene add to its applicability in diverse settings.
Polystyrene Foam – This material is ideal for projects necessitating closed cell foam blocks and is available in various densities to cater to different project needs. Known for its rigidity, polystyrene foam is extensively used for storage and packaging due to its resilience.
Neoprene Rubber – Available in rolls or sheets, neoprene rubber suits applications prioritizing cleanliness and insulation. It's commonly used for flooring, wall paneling, and athletic equipment. Resistant to mildew, mold, and bacteria, neoprene is appropriate for sports venues, daycares, and medical establishments.
Gym Rubber – Known for its high density and moderate firmness, gym rubber provides significant shock resistance with a slight bounce, making it perfect for daycares, gyms, and building insulation. It is offered in different densities and sizes, providing a viable choice for maintaining cleanliness and safety.
Polypropylene Foam – For heavy-duty applications requiring foam with substantial rigidity, polypropylene foam stands out. Its high density is particularly useful in protective packaging scenarios requiring strong protection.
The creation of foam involves capturing gas within a liquid, followed by applying pressure and heat to solidify it. Depending on its design, foam can provide benefits such as impact cushioning, noise reduction, safety enhancement, and waterproofing. In its solid state, closed-cell foam is non-toxic and is widely utilized in medical applications. However, in its initial gas or liquid forms, it can be harmful.
Widely recognized as one of the most effective insulation methods, closed-cell spray foam insulation offers exceptional energy efficiency. Its high thermal properties make it an ideal solution for both residential and commercial applications, ensuring enhanced thermal conversion.
For slicing through closed-cell materials, the optimal tool is a straight, non-serrated blade, like those found in utility or crafting knives. These blades offer convenience due to their replaceability. For smaller tasks requiring less precision, scissors may suffice, though only for certain types and thicknesses of foam. Employ a straight edge for crisper cuts. Always cut on a stable surface to protect both the foam and the work environment.
Neoprene, Gym Rubber, Cross-Linked Polyethylene, and Polyethylene Roll possess nearly identical physical structures, allowing you to utilize similar cutting approaches across these materials.
When handling materials like neoprene, XLPE, gym rubber, or polyethylene rolls, assess the material's thickness first. For sheets no thicker than 1/8", sharp scissors could work, but their use is primarily confined to lighter, hobbyist projects due to the potential for uneven edges. For tasks like designing bath toy shapes or trimming card backings, scissors offer quick solutions. Polyethylene roll is notably receptive to scissor cuts due to its pliability.
For any project involving materials over 1/8" in thickness, a straight blade is advisable. The material's thickness determines the ideal cutting strategy using a knife.
The single pass-through technique is best for cutting through materials as thick as 1/2". This method entails making one steady cut to separate the material along the chosen line, achieving a neat edge. Foam sheets up to 1/2" thick are ideal for this method, as thicker foams might inhibit seamless blade progress. Use a sharp knife to avoid snagging on deeper cuts. It's crucial to secure the foam to prevent it from shifting to maintain smooth, precise cutting.
For closed-cell foams exceeding 1/2" thickness, a single pass-through cut is typically impractical, possibly resulting in jagged edges. In contrast, the multi-pass technique is more apt for thicker foams, involving several cuts with the blade, guided by an extended straight edge to ensure clean and precise cuts.
After setting the cutting line and positioning the straight edge, initiate cutting similarly to the single-pass approach. Rather than cutting entirely through in a single try, make light cuts into the foam, about 1/8" to 1/4" in depth, covering the material's total length with minimal pressure. Continue with these shallow passes, progressively deepening the cut until ultimately cutting through the entire thickness, resulting in a tidy, efficient edge.
Polyethylene, a popular closed-cell foam with various densities, impacts its rigidity, cell structure, and flexibility. At lesser densities, its cell arrangement becomes more irregular and bubbly, complicating the cutting process—making scissors unsuitable. For sheets beyond 1/2" in thickness, adopt the single-pass cutting process; for thicker sheets, utilize a multi-pass cutting formation for optimal results.
Closed cell foam insulation proves to be an outstanding option when seeking strong structural stability, energy efficiency, and water resistance. Besides these advantages, it offers extra perks—high-density foam provides superior insulation compared to traditional materials like polyester, polyethylene fibers, or foil.
Density of Closed Cell Foam - This type of insulation boasts a densely packed cellular framework.
Water Resistance - Its cellular arrangement makes closed cell foam a formidable response to water-related issues.
Moisture Control - Closed cell foam's ability to repel water helps extend the insulation's lifespan significantly.
Reduction of Air Currents - This foam aids in reducing convective processes within walls and roofing structures.
Air Quality Improvement - The dense composition of closed cell insulation considerably boosts indoor air quality by blocking out contaminants, dust, and preventing mold progression and moisture penetration.
When it comes to industrial closed cell foam production, selecting the right manufacturing equipment is essential for achieving consistent quality and efficiency. Closed cell foam, widely used in a range of industries such as construction, architectural insulation, automotive, marine, aerospace, packaging, and HVAC, is prized for its thermal insulation, water resistance, structural integrity, buoyancy, and sound dampening properties. As market demand rises for high-performance closed cell foams—especially polyurethane foam, polyethylene foam, spray foam insulation, and EVA foam—advanced manufacturing machines play a critical role in optimizing production output and material performance. Below, we provide an overview of five prominent closed cell foam machinery manufacturers whose solutions drive production for leading foam fabricators worldwide, helping users compare features and identify the best fit for their specific applications.
The Cannon Viking Series offers high-performance machinery engineered for both continuous and discontinuous closed cell foam production. Incorporating state-of-the-art precise mixing, foaming chemistry control, thermal management, and automated curing technology, these foam manufacturing systems cater to industries requiring rigid polyurethane, polyisocyanurate, and polyethylene foam. Cannon Viking’s commitment to advanced process automation ensures reliable, repeatable foam cell structure and minimizes material waste, making it an industry leader for companies seeking scalable and efficient foam production solutions.
Hennecke is a global powerhouse providing high-pressure metering machines that set the benchmark in closed cell foam manufacturing. Renowned for their precision metering, advanced polyurethane chemistry integration, and intelligent process controls, Hennecke machines handle both small-scale and high-volume production needs. Their flexible systems enable producers to formulate a wide variety of closed cell polyurethane foams and pour-in-place foam products, generating consistent density and fine cell structure—key factors in achieving superior insulation and energy efficiency. Hennecke stands out for those prioritizing quality control, automated recipe management, and the ability to rapidly scale operations.
Linden Industries specializes in North American-manufactured high-pressure foam machines engineered specifically for closed cell foam applications. Their equipment ensures accurate foam density control, superior cell uniformity, and compatibility with diverse foam chemistries, including rigid foam boards, spray foam, and specialty composites. By offering configurable machines, seamless integration with plant networks, and robust quality assurance protocols, Linden empowers manufacturers to meet demanding specifications for building insulation, automotive thermal management, and packaging solutions.
The Gusmer H-20/35 Pro is a popular choice among foam fabricators and spray foam contractors for its reliability and efficient high-pressure closed cell foam production. This model features precise chemical ratio control, advanced temperature management, and high-output spray performance, making it ideal for commercial spray foam insulation, roofing systems, and structural foams. With exceptional uptime and easy maintainability, Gusmer equipment enables manufacturers to boost productivity and maintain excellent foam quality even during intensive use.
Evonik Industries offers comprehensive high-pressure foam dispensing and mixing systems tailored for closed cell foam production across various sectors. Known for their innovative mixing heads, automated dosing technology, and ability to maintain tight tolerances over large production runs, Evonik systems deliver precise foam formulation control essential for energy-efficient insulation panels, specialty transportation foams, and technical bun stocks. Their adaptability allows users to switch between standard and specialty foam formulations with minimal downtime, optimizing versatility in fast-paced manufacturing environments.
As technology continues to evolve, equipment specifications and model features are updated frequently. To select the optimal closed cell foam production machinery for your business—whether your focus is on polyurethane foam blocks, spray foam application, or custom closed cell products—we recommend consulting directly with machine manufacturers, authorized distributors, or trusted industry advisors. Doing so ensures access to the most up-to-date technical specifications, automation capabilities, and service support, helping you future-proof your investment and achieve superior closed cell foam product quality.
For in-depth equipment comparisons, process optimization tips, and advice on maximizing foam yield and consistency, explore current industry publications, attend trade shows, or request on-site demonstrations from these leading equipment providers. High-performing closed cell foam production begins with informed machinery selection and seamless integration into your manufacturing operations.
Closed cell foam encompasses a broad range of foam materials, each engineered for specific performance and demanding applications across industries. Choosing the right type of closed cell foam is crucial for applications in packaging, construction, automotive, insulation, flotation, and sporting goods. Below, we outline the main types of closed cell foam and highlight their unique characteristics and recommended uses.
EVA (Ethylene Vinyl Acetate) foam is available in grades ranging from #2 to #8. Renowned for its exceptional flexibility, shock absorption, and resilience, EVA foam is widely used in sports padding, personal protective equipment (such as helmets, shin guards, and knee pads), hot tub and spa insulation, and marine bumpers. Because EVA foam can be easily molded and retains its shape under repeated pressure, it is ideal for cushioning, impact protection, and custom-molded applications. EVA closed cell foam is also water-resistant and maintains buoyancy, which is essential for various outdoor and marine environments.
FloTex foam features medium firmness and a distinctive rubber-like texture, making it a highly versatile foam solution for several industries. Common applications include boat cushions, yoga mats, camping sleeping pads, and personal flotation devices. Thanks to its superior water repellency and ability to withstand prolonged exposure to moisture, FloTex foam is especially suited for marine applications, recreational products, and equipment that may be exposed to damp environments. Its closed cell structure ensures long-term durability, buoyancy, and mold resistance.
Polyethylene closed cell foam is commonly manufactured into versatile rolls of varying thickness and density. Thicker rolls deliver greater durability, mechanical strength, and insulation value compared to thinner varieties. Polyethylene foam rolls are trusted for applications including piping and plumbing insulation, medical device cushioning, automotive gaskets and seals, sports equipment padding, and packaging solutions. These rolls are chemically resistant, lightweight, and available in diverse types, shapes, and thicknesses to meet a wide range of performance requirements.
Cross-linked polyethylene foam (XLPE) stands out due to its refined and uniform cell structure, which delivers enhanced moisture and chemical resistance. XLPE foam is impervious to air, water, stains, mold, and mildew, and offers an aesthetically pleasing appearance. This makes it a preferred choice for premium packaging, medical device protection, construction thermal insulation, and marine flotation devices. Its unique cross-linking process provides improved structural integrity, better compressive strength, and higher dimensional stability compared to non-crosslinked foams, extending product durability in demanding environments.
Cross-linked foam features a more refined and consistent cellular structure compared to non-cross-linked varieties. In cross-linked foam, the polymer chains are interconnected, enhancing its stability, durability, and structural integrity. It is easier to handle, recyclable, and less abrasive. Furthermore, cross-linked foam demonstrates superior performance in applications requiring precise fabrication and tight tolerances. Both cross-linked and non-cross-linked foams are waterproof closed cell materials with excellent resistance to moisture and air, but cross-linked options offer increased longevity where repeated flexing or pressure is expected.
Understanding the distinctions between open cell foam and closed cell foam is crucial when selecting the right insulation or cushioning product:
Cell Structure - Open cell foams have interconnected cells, producing a soft and flexible material that readily allows air and moisture movement. Conversely, closed cell foams are constructed from completely enclosed cells tightly packed together, effectively trapping air and blocking moisture, resulting in a denser, more rigid material ideal for thermal insulation and water-resistant applications.
Density - Closed cell foam typically possesses higher density and compressive strength—often greater than 1.75 pounds per cubic foot—benefiting energy efficiency and load-bearing applications. Open cell foam generally measures around 0.5 pounds per cubic foot, making it lighter and more suitable for soundproofing and lightweight cushioning.
Expansion - Spray applications of closed cell foam yield about 1 inch thickness per layer, allowing for multi-layer installation to boost R-values and insulation performance (approximate R-value of 7 per inch). Open cell foam can expand up to 3 inches thick in one application, typically meeting standard wall insulation needs in a single pass.
Resistance to Air, Moisture, and Liquids - Closed cell foam resists water absorption due to its locked cellular structure, ensuring reliable vapor and moisture barrier performance—essential for roofing, subfloors, and foundation insulation. Open cell foam, with its open network, absorbs water and is better suited for interior sound absorption and non-moisture-exposed environments.
Material Cost - Open cell foams, such as polyurethane foam, tend to be more affordable due to their lighter structure and cheaper raw materials. These are common in furniture upholstery, carpet underlayment, and foam filters. In contrast, closed cell foam generally comes at a higher price point because of its enhanced performance benefits in strength, durability, and insulation.
Sound and Thermal Insulation - Closed cell foam outperforms with superior thermal insulation properties, making it a top choice for insulating walls, roofs, pipes, and ducts. On the other hand, open cell foam is preferred for soundproofing applications, effectively dampening ambient noise due to its open-path cellular structure.
Applications - Open cell foams are soft and compressible—ideal for sponges, packaging inserts, sound dampening materials, and filtration media. Their flexibility and shock-absorbing qualities offer versatility at a lower cost. Closed cell foams, because of their higher density and robust manufacturing process, are the go-to solution for water-resistant gaskets, marine flotation aids, HVAC insulation, automotive seals, and long-lasting protective packaging.
When evaluating spray foam insulation, it’s important to understand how open-cell vs closed cell spray foams perform in real-world scenarios. Open-cell foam, characterized by its low-density structure and suspended bubble network, is inherently more vapor-permeable—making it unsuitable as a full moisture barrier in wet environments. Closed-cell spray foam, manufactured with an insulating blowing agent, produces a rigid, high-density material that forms a comprehensive barrier against air and water infiltration, significantly improving energy efficiency and building envelope performance.
Both open-cell and closed-cell foam insulation options contribute to substantial energy savings and increased comfort. However, the main distinction lies in their respective costs and benefits. Open-cell spray foam is cost-effective, easier to install, and best for interior soundproofing, whereas closed-cell spray foam, though higher in material cost, pays off by enhancing structural strength and moisture protection, and by delivering much higher R-values per inch. For critical air sealing and high-performance insulation, closed-cell spray foam is the industry standard. Regardless of the foam type, always consult a professional spray foam installer for safe and reliable results, proper application thickness, and compliance with local building codes.
To select the optimal foam material for your project, consider the following key application requirements and user needs:
Additionally, consider the foam’s compressive strength, thickness, long-term performance, fire rating requirements, and compatibility with adhesives or lamination processes. If you are unsure which foam best fits your use case, consult with closed cell foam manufacturers or fabricators for expert recommendations tailored to your industry and application needs.
This chapter will explore the various applications and advantages of closed cell foam.
Closed cell spray foam insulation is both durable and sustainable, making it an excellent choice for commercial properties. Its superior strength compared to open-cell insulation makes it particularly well-suited for:
To clean closed cell foam, consider using a foam cleaner designed for automotive interiors or for spot treatments on carpets. Closed cell foam is resistant to strong acids and detergents, which means you can clean it effectively without needing to replace it or use abrasive tools like Scotch pads.
Closed cell foam is made by applying a gas, like nitrogen, to a plastic or rubber compound that is under high pressure. The foam can be made by exposing it to the gas directly, or by adding gas-forming agents into the material. Closed cell foam has air trapped in its cells, making it resilient, strong, impact resistant, and buoyant. The uses and applications:
The merits of using closed cell foam outweigh the demerits. There are different techniques used to cut the form which are: the single-pass cutting method and the multi-pass cutting method. They are different types of closed cell foam namely volara, EVA, and polyethylene foams to mention only a few. It can be found in different colors and thicknesses. They can be used indoors and outdoors and are also suitable for domestic and industrial purposes. They are relatively cheap.
It is possible to recycle polyethylene foam. It is possible to melt down the polythene foam and reform it the same way used on other plastic materials. Standard polyethylene foam is not resistant to fire, it can burn if in direct contact with flames. However, it will burn if it’s subjected to very high temperatures or if it is put in flames.
Closed-cell spray foam insulation consists of cells that are enclosed and securely packed together, as different in open-cell spray foam. Of all insulating materials found on the market, closed-cell spray foam insulation exhibits one of the highest R-values because of its extraordinarily high density. This makes it fall among the most energy-efficient choices available.
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