EPE XL (Cross-linked PE foam)
Grade
Choose the cross-linked (XPE/IXPE) foam when you need fine cell structure, smooth surface, low compression set and thermoformability; it costs about 2–4× the non-crosslinked foam.
Values for the XL condition
Other EPE grades and fills
EPE is listed in 6 conditions; see the grade overview at EPE.
Compare all 6 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
Low density foam, 12–18 kg/m³ | Pick the 12–18 kg/m³ foam for lightweight void fill and surface scratch wrapping: lowest cost per unit weight, but limited cushioning load capacity. | — | 0.15 | 70 | 6 Shore A |
Flame-retardant EPE | Specify the flame-retardant version (UL94 V-2 / GB 8624 B1) for rail transit interiors, building linings and electrical cabinet padding with fire requirements. | — | 0.22 | 65 | 12 Shore A |
Conductive (carbon-loaded) EPE, 10^4–10^6 Ω | Use the carbon-loaded conductive foam for component trays and liners that need a discharge path at 10^4–10^6 Ω; accept carbon rub-off and higher cost. | — | 0.28 | 70 | 13 Shore A |
Medium density foam, 28–35 kg/m³ | Choose the 28–35 kg/m³ foam for moulded or routed inserts holding medium-weight products, balancing load bearing against rebound. | — | 0.3 | 95 | 12 Shore A |
High density foam, 45–60 kg/m³ | Pick the 45–60 kg/m³ foam for repeated-drop protection of heavy appliances and electromechanical products — highest load bearing, at higher material cost. | — | 0.5 | 110 | 22 Shore A |
XLThis page Cross-linked PE foam | Choose the cross-linked (XPE/IXPE) foam when you need fine cell structure, smooth surface, low compression set and thermoformability; it costs about 2–4× the non-crosslinked foam. | — | 0.5 | 130 | — |
What is EPE XL?
EPE XL is EPE in the XL grade — choose the cross-linked (XPE/IXPE) foam when you need fine cell structure, smooth surface, low compression set and thermoformability; it costs about 2–4× the non-crosslinked foam. EPE XL has a tensile strength of 0.5 MPa (0.0725 ksi), weaker than 89% of polymer grades. Elongation at break is 130% and the elastic modulus is 0 GPa (2.9×10⁻⁴ Msi). EPE XL has a density of 0.03 g/cm³ (0.0012 lb/in³), lighter than 92% of polymer grades. Its glass-transition temperature is -110°C (-166 °F).
Advantages
- Forms and bends easily — 95/100, better than 99% of polymer grades
- Lightweight — 0.03 g/cm³ (0.0012 lb/in³), better than 92% of polymer grades
- Easy to machine — 85/100, better than 88% of polymer grades
- Low embodied carbon — 2.8 kg CO₂/kg, better than 86% of polymer grades
- Good corrosion resistance — 90/100, better than 82% of polymer grades
Limitations
- Low stiffness — 0 GPa (2.9×10⁻⁴ Msi), worse than 95% of polymer grades
- Poor heat conductor — 0.04 W/m·K (0.0202 BTU/hr·ft·°F), worse than 93% of polymer grades
- Degrades in UV without stabilisers — 25/100, worse than 76% of polymer grades
EPE XL properties
Typical room-temperature values for EPE XL; 10 are specific to this condition. Other listed values are EPE reference data and may not represent this condition. Bars are the position among polymer grades.
Physical4
EPE XL has a density of 0.03 g/cm³ (0.0012 lb/in³), lighter than 92% of polymer grades. Its glass-transition temperature is -110°C (-166 °F).
Mechanical8
EPE XL has a tensile strength of 0.5 MPa (0.0725 ksi), weaker than 89% of polymer grades. Elongation at break is 130% and the elastic modulus is 0 GPa (2.9×10⁻⁴ Msi).
Thermal8
EPE XL is rated for continuous service to 95°C (203 °F). It conducts heat at 0.04 W/m·K (0.0202 BTU/hr·ft·°F), worse than 93% of polymer grades. Thermal expansion is 180 µm/m·K (100 µin/in·°F).
Electrical6
EPE XL is an electrical insulator with a dielectric strength of 2.5 kV/mm (63.5 V/mil) and a resistivity of 1×10¹⁴ Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (90/100), better than 82% of polymer grades. UV resistance is poor.
Sustainability4
Producing a kilogram of EPE XL takes about 90 MJ of energy and emits 2.8 kg of CO₂ — less than 75% of polymer grades. Typical recycled content is 10%.
Manufacturability5
EPE XL's machinability is excellent (85/100, better than 88% of polymer grades); weldability very good (70/100); formability excellent (95/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with EPE XL
Is EPE easy to machine?
Cut with hot wire, bandsaw, steel-rule die or waterjet. CNC routing needs a sharp single-flute cutter with vacuum hold-down, fast feed and moderate spindle speed to avoid melting and smearing.
Can EPE be welded?
Hot-air gun or hot-plate fusion and hot-melt adhesive both work well, and multiple sheets can be welded into thick blocks. Solvent bonding is ineffective; corona or flame treatment is needed before conventional adhesives.
Can EPE be formed, bent or molded?
After extrusion foaming, allow 1-3 days of ageing to degas. Non-cross-linked sheet can be hot-pressed, grooved and coil-formed; cross-linked XPE can be vacuum or compression thermoformed into complex liners.
What surface finishes work on EPE?
Screen printing and heat transfer are possible after corona treatment, and sheet can be laminated with metallised or PE film, die-cut and grooved. No plating, and avoid solvent-based paints, which attack the cell structure.
EPE chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| physical blowing agent (butane/pentane rgradually replaced by air after foaming; requires curing | 0.2 – 3 | 1 |
| talc (nucleating agent) | 0.3 – 2 | 1 |
| glycerol monostearate / permeability & aantistatic grades add agent; conductive add 3–8 % carbon black | 0.5 – 2.5 | 1.2 |
| colour masterbatch / FR additive (option | 0 – 10 | 0 |
| ethylene (LDPE base resin)LDPE; some formulations add LLDPE/EVA for toughness | ≥ 92 (balance) | — |
EPE XL — frequently asked
What is EPE XL used for?
EPE XL is typically used for protective packaging cushioning, thermal/acoustic insulation liner, floor underlayment and shock-absorbing case inserts. In short: lightest PE cushioning form; low-cost protective packaging; closed-cell, moisture resistant.
What is the tensile strength of EPE XL?
EPE XL has a typical tensile strength of 0.5 MPa (0.0725 ksi) — weaker than 89% of polymer grades. Strength varies by condition: see the 6 listed tempers.
Is EPE XL easy to machine?
Yes — machinability is rated excellent (85/100, better than 88% of polymer grades). Cut with hot wire, bandsaw, steel-rule die or waterjet. CNC routing needs a sharp single-flute cutter with vacuum hold-down, fast feed and moderate spindle speed to avoid melting and smearing.
Can EPE XL be welded?
Yes — weldability is rated very good (70/100). Hot-air gun or hot-plate fusion and hot-melt adhesive both work well, and multiple sheets can be welded into thick blocks. Solvent bonding is ineffective; corona or flame treatment is needed before conventional adhesives.
What surface finishes work on EPE XL?
Screen printing and heat transfer are possible after corona treatment, and sheet can be laminated with metallised or PE film, die-cut and grooved. No plating, and avoid solvent-based paints, which attack the cell structure.
Can EPE XL be formed, bent or molded?
After extrusion foaming, allow 1-3 days of ageing to degas. Non-cross-linked sheet can be hot-pressed, grooved and coil-formed; cross-linked XPE can be vacuum or compression thermoformed into complex liners.
What is the maximum service temperature of EPE XL?
EPE XL is rated for continuous use to about 95°C (203 °F), and briefly to 90°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
Sources
- ASTM D3575 Flexible Cellular Materials Made from Olefin Polymers — ASTM (2020)
- Polyethylene foam (Cell-Aire / Ethafoam) product data — Sealed Air / DuPont (2022)
- Alveolit / Alveolen cross-linked PE foam data sheets — Sekisui Alveo (2023)
- Handbook of Polymeric Foams and Foam Technology — Hanser (2004)
Property data is compiled from published supplier and standards handbooks and normalised for comparison. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.