Laminated Polyethylene Foam

At Archbond, we have over 30 years of experience producing durable, high-quality laminated polyethylene foam at our in-house facility, always delivering reliable results, fast turnaround and industry-ready performance.

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If you need a product that can take a beating, absorb sound or keep heat in (or out), then laminated polyethylene foam is perfect. Polyethylene (PE) is a strong and resilient material with excellent shock absorption abilities. It's rigid enough to be used in many ways without showing any wear or tear over time. Laminating PE foam together creates endless options for thickness, colour and density.

Laminated polyethylene foam is used in an array of applications across a wide range of sectors, including packaging, construction and automotive. It is prized for its durability, strength and resistance to moisture. Laminated foam can also be printed on and die-cut into shapes, making it a versatile material for a wide range of products.

PE foam provides optimal cushioning protection against impact, and is ideally suited to shock absorption, dampening, insulation and buoyancy, making it a go-to for everything from camping mats and buoyancy aids to soundproofing panels and thermal barriers. Adhesive and non-adhesive PE is commonly used for packaging, joining, mounting, gasketing and sealing irregular surfaces.

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Sectors We Serve

We work with clients across many sectors to deliver high-performance laminated polyethylene foam solutions that meet both strict technical demands and commercial requirements. From shock-absorbing sports gear to moisture-resistant automotive insulation, our tailored fabrications are engineered for durability, flexibility and long-lasting results. Quality is assured with Archbond.

Sports

Swimming

For swimming pools, we manufacture laminated polyethylene foam materials for high-performance pool covers, helping reduce heat loss, minimise condensation and support energy efficiency. Our tailored covers are trusted by leisure centres, spas and residential clients alike.

Equestrian

Our laminated PE foam is used to produce a range of lightweight, flexible materials for equestrian products, including girth straps, saddle padding and other protective gear. This kind of laminated foam gives excellent comfort, durability and shock absorption, making it a modern, vegan-friendly alternative to traditional leather products.

Sportswear and Equipment

We produce components for performance-driven gear such as rucksack straps, head guards and safety harnesses with advanced laminated polyethylene foam. These materials are impact-resistant, flexible and long-lasting – absolutely ideal for manufacturers working across the sportswear and equipment sector where protection and comfort are so important.

Automotive

Our PE foam products support applications across the automotive sector, including thermal insulation for car transmission tunnels, seat padding and door panel cushioning. The foam’s heat resistance, dimensional stability (meaning it holds its shape and doesn't warp over time), and shock-absorbing properties make it reliable for improving both safety and comfort in vehicle interiors.

Industrial

Our laminated polyethylene foam is used in a range of industrial applications where resilience, hygiene and protection are essential. From ‘soft landing’ conveyor belts for transporting fresh produce to flooring and insulation components in commercial environments, the material’s lightweight, moisture-resistant and durable nature makes it ideal for demanding conditions.

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Premier Polyethylene Foam Specialists

End to End Solution

In House Manufacturing Service

Lightweight

Water resistant

Cost Effective

Benefits of Laminated Polyethylene Foam for Businesses

Laminated PE foam is a lightweight, resilient and flexible material that provides excellent energy absorption and cushioning. It is widely used in protective packaging and multi-use applications where durability and cost-efficiency are key.
Thanks to its fine-celled, chemical cross-linked closed-cell structure, PE foam is both strong and smooth-finished. What this means is that it keeps its shape under pressure, resists tearing and doesn't flake or crumble over time, making it ideal for repeated use and demanding environments.

Laminating the material enhances these properties even further, creating a product that performs reliably in high-volume manufacturing across varied industrial applications. Whatever your sector, laminated polyethylene foam’s combination of shock absorption, flexibility and surface consistency makes it a dependable choice.

It can also be fabricated into various shapes, sizes and colours. Anti-static options are available to support electronics and sensitive applications, and with our in-house fabrication, every product is customised to your exact specifications, with quick turnarounds and strict quality control.

Key properties of the foam include:

Lightweight, water-resistant and cost-effective
Superb strength and tear resistance
High shock absorption
Flexible and shatterproof
Air-tight and floats on water
Ultra-smooth surface cell structure
Impervious to mildew, mould, rot and bacteria
Superior chemical and grease resistance

The Laminated Polyethylene Foam Process

Laminated polyethylene foam is created by bonding layers of PE to achieve a specific thickness, strength or finish. At Archbond, this process is carried out in-house using specialist machinery and techniques such as hot lamination, infrared lamination and PUR adhesive lamination, each offering unique benefits depending on the required application. These methods allow us to tailor the structure and performance of the foam for everything from industrial insulation to packaging liners.

Laminating the foam in layers allows us to precisely control the thickness, density and finish, creating anything from thin, flexible sheets to thicker, more rigid formats depending on your needs.

The foam’s composition plays a vital role in the lamination process. It ensures the material maintains its integrity under pressure, doesn’t deform or absorb moisture and can be fabricated into a wide range of colours, densities and finishes. The foam is non-toxic to humans and, with anti-static options also available, supports everything from food-safe conveyor belts to sensitive electronics. And because polyethylene is 100% recyclable (as a class 4 material), the finished laminates offer not just performance, but long-term sustainability too.

Why Choose Archbond for Laminated Polyethylene Foam?

With over three decades of experience and a fully in-house manufacturing setup, we deliver laminated polyethylene foam solutions that are built to perform and engineered for durability. From the initial design stage to the final lamination, our dedicated engineers are in full control of every stage of the process. This helps us ensure fast turnaround, consistent quality and total flexibility over your required thickness, finish and performance needs.

Whether you’re manufacturing protective equipment, insulating components or soft-landing conveyor systems, we’ll tailor each order to meet your exact requirements, with expert support every step of the way. All materials are produced under ISO-accredited conditions at our Leicester facility. These are just some of the reasons that make Archbond the long-term contract lamination partner of choice for so many UK manufacturers.

Call us today on 0116 284 1222, email sales@archbond.com or use our contact form to get started.