PE Foam Board XL (XLPE)
Grade
ASTM D3575 · GB GB/T 25325
Step up to crosslinked foam when you need fine uniform cells, a smooth skin, better thermoformability and higher heat/compression-set performance.
Values for the XL condition
Other PE Foam Board grades and fills
PE Foam Board is listed in 11 conditions; see the grade overview at PE Foam Board.
Compare all 11 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
15 kg/m³ ultra-low-density plank | Cheapest surface-protection and void-fill foam for light, non-fragile goods. | 0.01 | 0.15 | 50 | 6 Shore A |
25 kg/m³ light-duty plank | Light cushioning and interleaving where a little more resilience than 15 kg/m³ is needed. | 0.02 | 0.25 | 65 | 10 Shore A |
EVA-modified / PE-EVA copolymer plank | Softer, more resilient and lower-set foam for repeated-impact padding, sports and footwear inserts. | 0.03 | 0.7 | 180 | 8 Shore D |
ESD / anti-static (pink) plank | Pick when packing PCBs and electronic assemblies that need static-dissipative surfaces. | 0.04 | 0.33 | 75 | 13 Shore A |
Flame-retardant plank | Choose for automotive interior, rail and building applications with burn-rate requirements. | 0.04 | 0.3 | 60 | 14 Shore A |
Conductive (carbon-loaded, black) plank | Use for Faraday-cage style packing of ESD-sensitive devices requiring <10⁶ Ω surface. | 0.05 | 0.32 | 60 | 14 Shore A |
45 kg/m³ medium-density plank | Higher static load per unit area for heavier tools, instruments and reusable dunnage. | 0.05 | 0.48 | 100 | 17 Shore A |
60 kg/m³ high-density plank | For heavy dunnage, machine-tool trays and buoyancy blocks needing firm support and low deflection. | 0.08 | 0.62 | 110 | 22 Shore A |
90 kg/m³ extra-high-density plank | Structural-grade foam core for buoyancy floats, fender pads and heavy repeat-impact dunnage. | 0.15 | 0.95 | 130 | 32 Shore A |
PE-33Default 33 kg/m³ general-purpose plank | The industry workhorse density: best balance of cushioning curve, cost and cut-quality for case inserts and edge protection. | — | 0.35 | 80 | — |
XLThis page XLPE | Step up to crosslinked foam when you need fine uniform cells, a smooth skin, better thermoformability and higher heat/compression-set performance. | — | 0.55 | 150 | — |
What is PE Foam Board XL?
PE Foam Board XL is PE Foam Board in the XL grade — step up to crosslinked foam when you need fine uniform cells, a smooth skin, better thermoformability and higher heat/compression-set performance. PE Foam Board XL has a tensile strength of 0.55 MPa (0.0798 ksi), weaker than 88% of polymer grades. Elongation at break is 150% and the elastic modulus is 0 GPa (1.45×10⁻⁴ Msi). PE Foam Board 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). PE-33 is the default condition FabDigit quotes; XL is available on request or by drawing note.
Advantages
- Lightweight — 0.03 g/cm³ (0.0012 lb/in³), better than 92% 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
- Low embodied carbon — 2.6 kg CO₂/kg, better than 89% of polymer grades
- Forms and bends easily — 85/100, better than 81% of polymer grades
Limitations
- Low stiffness — 0 GPa (1.45×10⁻⁴ Msi), worse than 98% of polymer grades
- Poor heat conductor — 0.04 W/m·K (0.0208 BTU/hr·ft·°F), worse than 92% of polymer grades
- Degrades in UV without stabilisers — 25/100, worse than 76% of polymer grades
PE Foam Board XL properties
Typical room-temperature values for PE Foam Board XL; 10 are specific to this condition. Other listed values are PE Foam Board reference data and may not represent this condition. Bars are the position among polymer grades.
Physical5
PE Foam Board 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
PE Foam Board XL has a tensile strength of 0.55 MPa (0.0798 ksi), weaker than 88% of polymer grades. Elongation at break is 150% and the elastic modulus is 0 GPa (1.45×10⁻⁴ Msi).
Thermal8
PE Foam Board XL is rated for continuous service to 95°C (203 °F). It conducts heat at 0.04 W/m·K (0.0208 BTU/hr·ft·°F), worse than 92% of polymer grades. Thermal expansion is 120 µm/m·K (66.7 µin/in·°F).
Electrical5
PE Foam Board XL has an electrical resistivity of 1×10¹³ Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (92/100), better than 91% of polymer grades. UV resistance is poor.
Sustainability4
Producing a kilogram of PE Foam Board XL takes about 85 MJ of energy and emits 2.6 kg of CO₂ — less than 79% of polymer grades. Typical recycled content is 10%.
Manufacturability5
PE Foam Board XL's machinability is excellent (88/100, better than 92% of polymer grades); weldability good (60/100); formability excellent (85/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with PE Foam Board XL
Is PE Foam Board easy to machine?
Cuts cleanly with band saw, hot wire, oscillating/drag knife or CNC router with single-flute sharp tooling; no lubricant, use vacuum hold-down and avoid melt smearing at high spindle speed.
Can PE Foam Board be welded?
Planks are laminated by hot-plate/hot-air fusion or contact adhesive; solvent cements do not work on PE and surfaces need flame or corona treatment before bonding or printing.
Can PE Foam Board be formed, bent or molded?
Sheets can be thermoformed/compression-moulded near 120–140 °C surface temperature, and skived, split or die-cut into inserts; non-crosslinked foam is less forgiving than XLPE and can collapse if overheated.
What surface finishes work on PE Foam Board?
No paint or plating; decorate with corona-treated printing, laminated films/foil, or fabric facing. Edges are usually left as cut or heat-sealed.
PE Foam Board 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 |
|---|---|---|
| talc (nucleating agent)cell-size control | 0.2 – 1.5 | 0.8 |
| glycerol monostearate (permeation/aging gas-exchange and antistatic aid | 0.3 – 2 | 1 |
| residual blowing agent (isobutane/butanediffuses out during curing/aging | 0.1 – 3 | 1 |
| colour / functional masterbatchcarbon black, antistat, FR as ordered | 0 – 4 | 0.5 |
| low-density polyethylene (LDPE)foam-extrusion grade, MFI ~0.2–4 g/10 min | ≥ 92 (balance) | — |
PE Foam Board XL — frequently asked
What is PE Foam Board XL used for?
PE Foam Board XL is typically used for industrial cushioning pads, float/buoyancy blocks, sound/vibration dampening, protective case liners and gasket and seal backing. In short: lowest-cost plank foam; non-crosslinked LDPE block stock; closed-cell and buoyant.
What is the tensile strength of PE Foam Board XL?
PE Foam Board XL has a typical tensile strength of 0.55 MPa (0.0798 ksi) — weaker than 88% of polymer grades. Strength varies by condition: see the 11 listed tempers.
Is PE Foam Board XL easy to machine?
Yes — machinability is rated excellent (88/100, better than 92% of polymer grades). Cuts cleanly with band saw, hot wire, oscillating/drag knife or CNC router with single-flute sharp tooling; no lubricant, use vacuum hold-down and avoid melt smearing at high spindle speed.
Can PE Foam Board XL be welded?
Yes — weldability is rated good (60/100). Planks are laminated by hot-plate/hot-air fusion or contact adhesive; solvent cements do not work on PE and surfaces need flame or corona treatment before bonding or printing.
What surface finishes work on PE Foam Board XL?
No paint or plating; decorate with corona-treated printing, laminated films/foil, or fabric facing. Edges are usually left as cut or heat-sealed.
Can PE Foam Board XL be formed, bent or molded?
Sheets can be thermoformed/compression-moulded near 120–140 °C surface temperature, and skived, split or die-cut into inserts; non-crosslinked foam is less forgiving than XLPE and can collapse if overheated.
What is the maximum service temperature of PE Foam Board XL?
PE Foam Board XL is rated for continuous use to about 95°C (203 °F), and briefly to 95°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between PE Foam Board PE-33 and PE Foam Board PE-90?
PE-33 is the default condition — the industry workhorse density: best balance of cushioning curve, cost and cut-quality for case inserts and edge protection. PE-90: structural-grade foam core for buoyancy floats, fender pads and heavy repeat-impact dunnage.
Sources
- ASTM D3575 – Standard Test Methods for Flexible Cellular Materials Made from Olefin Polymers — ASTM International (2020)
- JIS K 6767 – Cellular plastics, polyethylene – Methods of test — JSA (2009)
- Polyethylene plank foam (Ethafoam-type) property sheets — Sealed Air / Zotefoams / Furukawa (2023)
- Handbook of Polymeric Foams and Foam Technology — Hanser (2004)
- LDPE base-resin thermal and electrical property data — CAMPUS / producer resin datasheets (2023)
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.