EVA Foam XL
Grade
also Ethylene Vinyl Acetate Foam, EVA closed-cell foam
XL = chemically cross-linked closed-cell EVA foam
Pick for fine uniform cells, best resilience/compression-set recovery and thermoformability; standard for footwear and technical padding.
Values for the XL condition
Other EVA Foam grades and fills
EVA Foam is listed in 9 conditions; see the grade overview at EVA Foam.
Compare all 9 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
Low density (~0.035 g/cm³) soft closed-cell foam | Pick for lightest-weight cushioning, buoyancy and packaging voids where load-bearing is minimal. | — | 0.6 | 220 | 18 Shore A |
non-cross-linked (uncured) EVA foam | Cheapest option for one-shot packaging and low-duty padding; accepts heat welding and remelt scrap but takes more permanent set. | — | 0.8 | 170 | 28 Shore A |
Anti-static / conductive EVA foam | Pick for electronics trays, PCB and component packaging that must dissipate static charge. | — | 0.9 | 180 | 32 Shore A |
Closed CellDefault standard cross-linked closed-cell EVA foam sheet/bun | Default general-purpose skived or molded closed-cell EVA foam for padding, gaskets, midsoles and packaging. | — | 1 | 200 | 30 Shore A |
Medium density (~0.060 g/cm³) closed-cell foam | Workhorse density for shoe midsoles, sports padding and general gasketing. | — | 1 | 210 | 30 Shore A |
Flame-retardant EVA foam | Use where transit, rail, electronics or building specs require self-extinguishing cellular material. | — | 1 | 140 | 40 Shore A |
XLThis page Chemically cross-linked closed-cell EVA foam | Pick for fine uniform cells, best resilience/compression-set recovery and thermoformability; standard for footwear and technical padding. | — | 1 | 220 | 35 Shore A |
High density (~0.10 g/cm³) closed-cell foam | Pick when firmer support, better abrasion life and cleaner CNC/heat-formed edges are needed (cosplay armour, case inserts, outsole wedges). | — | 2 | 200 | 45 Shore A |
Very high density (~0.20 g/cm³) firm closed-cell foam | Choose for load-bearing pads, structural cosplay parts, orthotic posting and heavy-duty sealing where deflection must stay small. | — | 3 | 170 | 18 Shore D |
What is EVA Foam XL?
EVA Foam XL is EVA Foam in the XL grade — pick for fine uniform cells, best resilience/compression-set recovery and thermoformability; standard for footwear and technical padding. EVA Foam XL has a tensile strength of 1 MPa (0.189 ksi), weaker than 85% of polymer grades. Elongation at break is 220% and the elastic modulus is 0.01 GPa (8.7×10⁻⁴ Msi). EVA Foam XL has a density of 0.06 g/cm³ (0.0022 lb/in³), lighter than 88% of polymer grades. Its glass-transition temperature is -30°C (-22 °F). Closed Cell is the default condition FabDigit quotes; XL is available on request or by drawing note.
Advantages
- Forms and bends easily — 92/100, better than 97% of polymer grades
- Easy to machine — 88/100, better than 92% of polymer grades
- Good corrosion resistance — 92/100, better than 91% of polymer grades
- Lightweight — 0.06 g/cm³ (0.0022 lb/in³), better than 88% of polymer grades
- Ductile — tolerates forming and impact — 220%, better than 77% of polymer grades
Limitations
- Hard to polish — 10/100, worse than 98% of polymer grades
- Poor heat conductor — 0.04 W/m·K (0.022 BTU/hr·ft·°F), worse than 90% of polymer grades
- High mold shrinkage — 2.2%, worse than 87% of polymer grades
- Low stiffness — 0.01 GPa (8.7×10⁻⁴ Msi), worse than 86% of polymer grades
EVA Foam XL properties
Typical room-temperature values for EVA Foam XL; 18 are specific to this condition. Other listed values are EVA Foam reference data and may not represent this condition. Bars are the position among polymer grades.
Physical5
EVA Foam XL has a density of 0.06 g/cm³ (0.0022 lb/in³), lighter than 88% of polymer grades. Its glass-transition temperature is -30°C (-22 °F).
Mechanical10
EVA Foam XL has a tensile strength of 1 MPa (0.189 ksi), weaker than 85% of polymer grades. Elongation at break is 220% and the elastic modulus is 0.01 GPa (8.7×10⁻⁴ Msi).
Thermal9
EVA Foam XL is rated for continuous service to 80°C (176 °F). It conducts heat at 0.04 W/m·K (0.022 BTU/hr·ft·°F), worse than 90% of polymer grades. Thermal expansion is 180 µm/m·K (100 µin/in·°F).
Electrical4
EVA Foam XL has an electrical resistivity of 1×10¹² Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (92/100), better than 91% of polymer grades. UV resistance is fair.
Sustainability4
Producing a kilogram of EVA Foam XL takes about 75 MJ of energy and emits 3.4 kg of CO₂ — less than 91% of polymer grades. Typical recycled content is 15%.
Manufacturability8
EVA Foam XL's machinability is excellent (88/100, better than 92% of polymer grades); weldability good (55/100); formability excellent (92/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with EVA Foam XL
Is EVA Foam easy to machine?
Die-cuts, skives, hot-wire and drag-knife cuts cleanly; for CNC use single-flute sharp routers at high feed with vacuum hold-down — dull tools smear and melt the cells.
Can EVA Foam be welded?
Joins by contact/hot-air welding, heat lamination or hot-melt/contact adhesive (chloroprene, PU); surfaces should be scuffed or flame/plasma treated for structural bonds.
Can EVA Foam be formed, bent or molded?
Compression-molded from bun stock or heat-formed at roughly 110–140 °C surface temperature; expect 2–4 % shrinkage after demold and allow for skin formation on molded faces.
What surface finishes work on EVA Foam?
Seal the open cells of cut edges with heat, plasti-dip or flexible PU/latex primer before painting; flexible acrylic or PU topcoats only — rigid paints crack on flexing.
EVA Foam 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 |
|---|---|---|
| vinyl acetate (comonomer)higher VA = softer, more elastic foam | 15 – 30 | 20 |
| azodicarbonamide (blowing agent)chemical foaming agent, decomposes ~150–170 °C | 1 – 6 | 3 |
| dicumyl peroxide (crosslinker)omitted in non-cross-linked grades | 0.3 – 1.2 | 0.7 |
| ZnO / zinc stearate (activator, kicker) | 0.5 – 3 | 1.5 |
| CaCO3 / talc fillercost/stiffness adjustment | 0 – 15 | 5 |
| pigment, antioxidant, processing aid | 0.5 – 4 | 2 |
| ethylene (comonomer)EVA copolymer backbone | ≥ 70 (balance) | — |
EVA Foam XL — frequently asked
What is EVA Foam XL used for?
EVA Foam XL is typically used for shoe midsoles and insoles, sports and helmet padding, case and tool-tray inserts, packaging cushioning, low-load dust and splash gaskets and thermal insulation layers. In short: lightweight closed-cell EVA.
What is the tensile strength of EVA Foam XL?
EVA Foam XL has a typical tensile strength of 1 MPa (0.189 ksi) — weaker than 85% of polymer grades. Strength varies by condition: see the 9 listed tempers.
Is EVA Foam XL easy to machine?
Yes — machinability is rated excellent (88/100, better than 92% of polymer grades). Die-cuts, skives, hot-wire and drag-knife cuts cleanly; for CNC use single-flute sharp routers at high feed with vacuum hold-down — dull tools smear and melt the cells.
Can EVA Foam XL be welded?
Yes — weldability is rated good (55/100). Joins by contact/hot-air welding, heat lamination or hot-melt/contact adhesive (chloroprene, PU); surfaces should be scuffed or flame/plasma treated for structural bonds.
What surface finishes work on EVA Foam XL?
Seal the open cells of cut edges with heat, plasti-dip or flexible PU/latex primer before painting; flexible acrylic or PU topcoats only — rigid paints crack on flexing.
Can EVA Foam XL be formed, bent or molded?
Compression-molded from bun stock or heat-formed at roughly 110–140 °C surface temperature; expect 2–4 % shrinkage after demold and allow for skin formation on molded faces.
What is the maximum service temperature of EVA Foam XL?
EVA Foam XL is rated for continuous use to about 80°C (176 °F), and briefly to 90°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
Can FabDigit make parts in EVA Foam XL?
Yes — EVA Foam XL is available for injection molding; every part is priced by an engineer rather than instantly. Upload a STEP file to get a price and a DFM check.
Sources
- ASTM D3575 — Flexible Cellular Materials Made from Olefin Polymers — ASTM International (2020)
- ASTM D1056 — Flexible Cellular Materials, Sponge or Expanded Rubber — ASTM International (2020)
- UL 94 — Tests for Flammability of Plastic Materials (HBF/HF-1 cellular classes) — UL Solutions (2022)
- Alveolit / Alveolux cross-linked polyolefin & EVA foam data — Sekisui Alveo (2023)
- Evazote EVA foam grade data — Zotefoams (2023)
- Engineered Materials Handbook — Engineering Plastics (cellular plastics section) — ASM International (1988)
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.