Custom Foam Inserts: EVA vs PE vs PU Packaging Foam Guide (2026)
EVA vs PE vs PU Foam: Which Packaging Foam Is Best?
Die-cut foam inserts are the gold standard for protecting fragile products during shipping. But which foam type should you choose? Here's the complete comparison.
Quick answer: EVA foam for 90% of applications (best balance of protection, cost, and appearance). PE foam for lightweight items and budget applications. PU foam for heavy-duty industrial protection.
EVA Foam (Ethylene-Vinyl Acetate)
The most popular packaging foam — medium density with excellent impact absorption and a clean, professional appearance.
- Density: 25–45 kg/m³
- Feel: Firm but resilient, rubber-like
- Color options: Black, white, grey, red, blue, custom
- Cost: $0.50–$3.00/unit (standard insert)
- Fabrication: CNC routing, die-cutting, water-jet cutting
- Rebound: Excellent — returns to shape after compression
- Best for: Electronics, phones, tablets, glass items, cosmetics, watches
Why EVA Is #1
- Best balance of protection and cost
- Clean-cut edges look professional
- Doesn't crumble, shed, or leave residue
- Available in many colors for brand matching
- Widely used by Apple, Samsung, Dyson, and major brands
PE Foam (Polyethylene)
Softer, lighter foam with lower density. Available in cross-linked (smoother) and non-cross-linked (more affordable) varieties.
- Density: 18–33 kg/m³
- Feel: Soft, cushiony, lightweight
- Color options: White, black, pink (anti-static), blue
- Cost: $0.30–$2.00/unit
- Fabrication: Die-cutting, CNC routing
- Rebound: Good — softer compression recovery
- Best for: Light electronics, cosmetics, food trays, general merchandise
PE Advantages
- Cheapest foam option
- Extremely lightweight — minimal shipping cost
- Anti-static pink PE available for electronics
- Good for products that need gentle cushioning, not rigid support
PU Foam (Polyurethane)
Dense, firm foam with the highest impact absorption — used for heavy and industrial applications.
- Density: 40–80 kg/m³
- Feel: Firm, dense, minimal compression
- Color options: Dark grey, black, charcoal
- Cost: $0.80–$5.00/unit
- Fabrication: CNC routing (best for complex cavities)
- Rebound: Moderate — firmer, less spring-back
- Best for: Heavy equipment, tools, firearms, medical devices, industrial parts
Comparison Table
| Feature | EVA | PE | PU |
|---|---|---|---|
| Density | 25–45 kg/m³ | 18–33 kg/m³ | 40–80 kg/m³ |
| Cost | $0.50–$3.00 | $0.30–$2.00 | $0.80–$5.00 |
| Protection | ★★★★★ | ★★★☆☆ | ★★★★★ |
| Weight | Medium | Light | Heavy |
| Appearance | ★★★★★ Clean | ★★★☆☆ Basic | ★★★★☆ Industrial |
| Best for | Consumer electronics | Light items | Heavy equipment |
| Color options | Many | Limited | Limited |
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