A successful business starts when it provides its customers with their ordered products in perfect condition. Not broken, not damaged, and obviously not cracked. This level of protection and safety is only gained by packaging your product in custom boxes with proper inserts and dividers. They provide cushioning and shock absorption to your product. They give you a luxury and premium look.
Imagine you go to your shop and you find a huge crowd in front of your gift shop or glass product shop. And when you try to open your shop, customers ask you.
Hey, be in line! Can you just see we have been waiting here for the last 2 hours?
Or you have an online retail store for selling jewelry with premium magnetic boxes or providing digital & electronics or vintage & ancient products. And when you start your work, your notification box becomes loaded with orders.
And you are like, "Wooow!!"Do you know what is common in both of these situations? If you are thinking of a lot of customers, then MY DEAR Congratulations!! You have got my point.
“Customer satisfaction is the main point in running a successful business, and that is only gained and not purchased.”
There are many materials available in the market for making insert and divider products, but they fail to meet the expectations. Sometimes they break when inserting them in the boxes, or sometimes they break when a little pressure is applied. How can you rely on a material that can't just protect itself?
If you have also faced this kind of problem, then you need to try the real packaging insert hero material, “EVA foam”. And I can bet on it that it will convince you of itself. This material is durable, reliable, and stress crack-resistant.
In this blog, we will convince you why it is the best safety and cushioning partner in the industry. We will provide you with all the information based on decades of experience. Our certified team has great research on what EVA foam is, where you can buy it, and what its benefits are for your brand.
EVA foam is a very adaptable material that is becoming famous in creative and practical fields due to its lightweight. It is used in making ship floors and boat surfaces because of its water-resistant properties.
Moreover, it is also making its name in the world of cosplay for the formation of craft, armor, props, and costumes. It has the ability to bend and retain its original form.
This material possesses some other properties, like excellent shock absorption and chemical resistance. And most of all, it is easy to customize according to your product needs and requirements during shipping and transportation. Its durability is making many industries make their products, safety inserts, and dividers using this material.
We have read that EVA foam has several advantages and benefits for many industries. And many brands are using this material on a daily basis in their product packaging. The main question that arises in everyone’s mind is that. Which material is used in making all these products? The answer is very simple. "Ethylene, which is a petroleum-based plastic polymer, and vinyl acetate, which is a chemical compound used for softness and elasticity".
It is a high-performance rubber that has a closed-cell structure. This makes it a perfect product that provides protection and comfort. This material has very unique properties, which make it ideal for different products.
EVA foam is free from phthalates, heavy metals, latex, and BPA. This makes it a very suitable product for domestic applications for kitchen use. Moreover, they are perfectly non-toxic and safe for kids' toys.
It is used to make sports equipment, footwear, seating systems, protective gear, spa products, and safety paddings. It has low water absorption and offers high durability for long-term use. Moreover, it is stress- and crack-resistant and offers very good cushioning impact protection.
According to research done by HDIN Research on the topic of EVA Foam Market Insights 2026, Analysis and Forecast to 2031, the global ethylene-vinyl acetate EVA foam market is on a strong growth pathway.
It is expected that it will reach approximately USD 4.5 billion by 2026. This growth is expected to continue at a compound annual growth rate CAGR of 5% to 7% through 2031. This shows that it is playing its essential part in sustainable long-term market development. This growth is because of increasing demand across multiple end-use industries like footwear, packaging, automotive, and sports equipment. [Report Credit: HDIN Research]
There are many industries that are already investing in EVA foam due to its flexible nature and lightweight structure. You can also use this material to provide shock absorption and a cushioning effect to your products. This will make sure that your product reaches your customer in a safe and secure way. You can get benefits from material like
This enhances your customer satisfaction and high brand value in the market.
This will help you gain your customers' loyalty and brand recognition in the market.
You can increase your product safety and protection by using it as a custom insert.
It is a very lightweight material that can help you cut shipping and manufacturing costs.
This is a durable material and can become your long-term solution.
EVA foam is a very flexible, durable, and versatile polymer-based material. It is mostly used across many industries like automotive, building and construction, sports and recreation, footwear, healthcare, packaging, seating, consumer goods, and electronics. It has unique performance properties differentiated from many other types of foams.
EVA foam has a very closed cell structure, which makes it a perfect water- and moisture-resistant material. Its density ranges from "20 to 150 kg/m³," depending on its application. This gives manufacturers a perfect material that provides cushioning, structural support, and impact protection.
One of the main advantages of EVA foam is that it has "low thermal conductivity", which is "0.033 Wm.K". This makes it a very effective thermal insulating material as well. Moreover, it has a very good UV radiation resistance, which means that it can be used in making products that have to be used outdoors and for long-term exposure to sunlight.
EVA foam has a reliable "tensile strength of 0.3 to 0.5 MPa", and this means it is durable and resistant to degradation under normal conditions. This material is very strong and has very strong chemical resistance (chemicals, oils, and fuels). It is a perfect choice for industries and consumer products.
It is also known for its property that it can resist tearing under high stress. It can bear "elongation stress of around 200 to 600 percent" before breaking down. Moreover, it has a "shore hardness range from 25 to 60". This allows you to get it customized for different applications as per your requirements.
Note: If you are a gift business or a fragile item seller, you must use EVA foam that gives a luxury unboxing experience and protects items. But using an insert changes the dimensions of a box (length x width x height), so learn about how to measure a box dimension accurately. Read our comprehensive guide.
The ethyl vinyl acetate foam is made by mixing a polymer base with specific chemical additives. This mixture makes this material perfect for extension flexibility, cushioning effect, and durability.
During processing, some additives such as blowing agents, cross-linking agents, and stabilizers react under heat and pressure. They create this foam cellular structure and mechanical performance.
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EVA Foam Additives and Their Purposes |
|
|---|---|
|
Additive Type |
Purpose |
| Lubricants (Stearic Acid, PE wax) | Easier mixing and molding |
| Antioxidants | Prevent thermal degradation |
| UV Stabilizers | Outdoor durability |
| Color Pigments | Coloration |
| Flame Retardants | Fire resistance (if required) |
EVA foam is formed by the combination of ethylene and vinyl acetate through chemical bonding, which takes place in the presence of blowing agents. The whole process is done in the presence of heat and pressure to create a closed-cell structure.
There are different steps mentioned below that are involved in the process of making raw material preparation.
EVA foam or ethylene vinyl acetate foam is made in several steps.
This is the very first step in which the raw material is prepared. Ethylene vinyl acetate copolymers pellets are mixed with the foaming agents. These foaming agents are organic peroxides and stabilizers that are poured into the mixers.
Then that mixture is heated. To melt it to a liquid or dough-like state, this liquidity state makes it more easily flowable.
After heating the mixture, the liquid hot polymer mixture is then poured into the molds of the desired shape. These molds are made according to the requirements of the customers.
And in those molds, the melted EVA expands, and it takes the shape of that mold.
After the EVA foam is poured into the pre-formed EVA-shaped molds, it is heated and compressed to gain the final shape of the EVA foam.
This product is used for thicker items. Then the hot mixture is pushed out of the molds to create a sheet or profile, which is then cooled and rolled.
After molding, the foam cools, and its structure properly solidifies. After that solidification, the sheets are cut according to the required size of the product. They also undergo sanding and trimming to enhance their final look.
There is no doubt that EVA foam is a perfect protective packaging material. It is renowned for its properties in the packaging industry. It comes in two forms, that is, rolls and buns form blocks. We will look into each of these types to know more about this.
These are the foam rolls that are made as continuous sheets, and they are rolled up. They have a thickness from 1/32 inch to 0.5 inch. The roll has a width of 60 inches and has a density that ranges from 2 lb to 20 lb per cubic foot.
These rolls are easy to cut, and they are mostly used for lining and wrapping products. Moreover, you can use them in your rigid boxes or gift boxes for cushioning and shock absorption. They can also be used to protect your glass jars.
EVA foam buns are solid foam blocks, which are used when thicker protection is needed. They have a thickness from 1 inch to 4 inches, and their width is between 14 inches and 16 inches. Their length is between 48 inches and 72 inches, and their density ranges from 1.5 lb to 18 lb per cubic foot.
These foam blocks are cut into custom shapes for heavy-duty or shock absorptive packaging. And they are perfect for shipping boxes and storage boxes that are used for shipping and transportation.
After gaining knowledge of how beneficial it is for any business, you must utilize it to not only grow your business but also to make the unboxing experience and protection aspect long-lasting.
This material is known for its excellent energy return. This feature allows it to spring back to its original shape after compression. So it can be bent and reshaped as per your own preference.
EVA foam has a closed-cell structure. It means that its internal cells are sealed, which prevents the penetration of water. This makes it highly resistant to moisture absorption.
Because of this property, it is widely used in padding, flotation devices, and protective gear where moisture resistance is very important. It prevents the growth of mold and bacteria and makes it ideal for marine and outdoor uses.
EVA foam has strong resistance to ultraviolet radiation. It helps prevent the damage that is caused by sunlight, like degradation, discoloration, and loss of mechanical properties.
This makes it a perfect choice for making outdoor applications such as fishing rods, handles, marine products, sports equipment, and outdoor mats.
This material is totally chemically resistant to many chemicals, including oils, fuels, and solvents. Due to this resistance, it is suitable for using them in harsh chemical environments.
EVA is highly durable. It prevents wearing, tearing, and environmental stress and has excellent elastic recovery. This means that it can return to its original shape after compressing or bending. This property makes it reusable multiple times.
EVA foam is a highly flexible thermoplastic material. It means it can be easily molded, thermoformed, cut, or shaped into various sizes and designs. It will not lose its structural strength.
This is a very beneficial property for manufacturers who want to customize products for specific functions and requirements.
EVA foam provides very high shock absorption as compared to other natural rubber foams. Its cushioning performance is perfect for sport mats, protective padding, footwear, midsoles, helmets, and safety equipment.
EVA foam has a high resistance to stress cracking. You can even use them under repeated loads and pressures. Due to this, they make sure the product is reliable in demanding environments.
EVA foam is made up of closed cells, which makes it extremely lightweight. And it does not compromise on strength and durability. Due to this, it is used in various places where weight reduction is important, such as sporting goods, packaging, and protective products.
This material is a gem for many industries due to its outstanding properties and features. The application of this material is very wide. Some top industries are mentioned below as a reference.
EVA foam is used in the gift industry as protective packaging. It is used for making custom inserts and decorative designs. These not only give your gift boxes a premium look but also keep your delicate items safe during transport and shipping.
These are lightweight and easy to shape material, which makes them ideal for both packaging and creative gift applications.
EVA is widely used in the sporting and fitness industries for making their safety gadgets and equipment. It is preferred over other materials because it offers perfect impact absorption and shock-damping properties.
Moreover, it also reduces the risk of injuries during high-intensity sports. Some common applications of EVA in this industry are given below.
+ Helmet and protective padding
+ Knee and elbow guards
+ Gym flooring and exercise mats
+ Yoga mats and training equipment
In the footwear industry, those materials are preferred that provide cushioning, shock absorption, and arch support. That is why EVA is used because it increases the comfort and performance. It is commonly used in
+ Athletic shoe midsoles
+ Insoles and flip-flop soles
+ Sandals and casual footwear
EVA foam is known for its water resistance, durability, and long-term cushioning effects. That is why it is used in the seats. Some applications are given below.
+ Marine seats and boats and yachts decking
+ Stadium seating
+ Outdoor furniture
In the sports industry, safety products are very important. They are used for energy absorption during high impacts. That is why EVA foam is used for shock absorption and cushioning capabilities.
It is used in personal protective equipment PPE and sports safety products. The application of EVA foam in protective gear includes
+ Helmet liners
+ Knee and elbow pads
+ Shin guards and protective body protection inserts
EVA foam has a closed-cell structure, and buoyancy makes it a perfect choice for water-related product manufacturing. It includes
+ Pool noodles and floating devices
+ Swim training aids
+ Spa pillows and poolside comfort accessories
EVA is perfectly known for protective cushioning and insulation material in shipping and transportation. It is used by the custom box manufacturers to make products that can protect fragile items during shipping. It is also used for making custom foam inserts for reducing vibration and shock in transportation.
EVA foam sheets are easy to cut, shape, glue, and thermoform, and this makes them a very demanding material in creative industries. They are used for making
+ Cosplay costumes, armors, and props
+ Model making
+ Decorative and craft projects
EVA foam is a children's toy manufacturer's first choice because of its non-toxic and safe properties. It is considered safe for use in children's products like
+ Foam building blocks
+ Puzzle mats
+ Educational play items
EVA foam is highly used in the healthcare industry for making products due to its cushioning and supportive properties. It is used in making different products like
+ Orthopedic insoles
+ Prosthetic liners and components
+ Medical protective padding
EVA foam is used in building and construction sites due to its thermal insulation, soundproofing, and cushioning properties. They are also used in tiles and interior design items to make them better materials.
EVA foam is known for its perfect insulation and impact protection properties. That is why it is used for making temperature-controlled packaging boxes where certain medical supplies and pharmaceuticals are required to be transported in a controlled temperature environment.
Note: “If you work with rigid boxes for giving premium and luxury unboxing experience, then you can use our EVA foam inserts for durable shipping and transportation.”
Many users often ask why EVA foam is considered a better option compared to other types of foam. The answer is very straightforward. It offers you durability, flexibility, and safety in a way that most other foams cannot offer you.
The table below highlights the main reasons why EVA foam is your preferred choice.
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EVA Foam Type Comparison for Packaging and Cushioning |
||||
|---|---|---|---|---|
|
Features |
EVA Foam |
Polyurethane (PU) Foam |
Polyethylene (PE) Foam |
Memory Foam |
| Softness & Flexibility | Soft, flexible, resilient; good for cushioning | Softer than EVA; can be very flexible or firm depending on formulation | Generally firmer and less flexible | Very soft and conforms to body shape; slow rebound |
| Durability | High durability; resistant to cracking and deformation | Moderate; can degrade faster under heat or moisture | Very durable; maintains shape under stress | Moderate; can lose shape over time |
| Shock Absorption & Cushioning | Excellent shock absorption; widely used in sports, footwear, and mats | Good cushioning; often used in furniture and mattresses | Moderate; more for packaging and insulation | Excellent body-conforming cushioning; not ideal for heavy impact |
| Water & Moisture Resistance | Highly water-resistant; does not absorb moisture | Absorbs some moisture; can degrade if wet | Excellent water resistance; ideal for marine or packaging | Absorbs moisture; not suitable for wet environments |
| Chemical Safety | Non-toxic when produced properly; phthalate-free, BPA-free | Varies; may contain isocyanates or other additives | Generally safe; inert material | Safe, but chemical additives may vary by manufacturer |
| Temperature & Heat Resistance | Good heat resistance; can handle moderate heat without deformation | Moderate; may degrade at high temperatures | Excellent; retains shape under heat | Sensitive to high heat; may deform |
| Cost | Affordable | Most Affordable | Most Affordable | Most Expensive |
Note: If you want to use EVA foam in your hardware boxes as a packaging insert, you can contact us for a free instant quote with free sample kits and free delivery. Order now.
Ethylene vinyl acetate is generally a very safe and non-toxic polymer when it is manufactured properly for consumers. It is widely used in products that come in skin contact due to its softness, flexibility, and chemical stability.
There is a very common question that is being asked by users. Whether EVA foam is toxic or has any safety concerns, most importantly for children. “The answer is NOOooo”.
When you use high-quality EVA foam products, they are typically phthalate-free, BPA-free, latex-free, and free from all those heavy metals. These are the main reasons that can cause any kind of harm. It does not have any harmful substances, but the overall product safety is based on the additives and the controls used by manufacturers.
Reputable manufacturers like “MyBoxPrinting” make sure that residual chemicals and processing agents are within regulated safety limits.
EVA material meets and exceeds US and European safety benchmarks. Moreover, this material is approved by many safety and health regulatory authorities for use in different products. The regulatory authorities are given below for EVA foam.
FDA Food Contact Safety:
It meets specific standards that are considered food safe and is approved for food packaging. It complies with the “FDA 21 CFR 177.2600 test”.
ASTM International:
There are many EVA products, like children's play mats and footwear. These are tested against ASTM standards, especially “ASTM F9634”. This makes sure that they are safe for skin contact and do not have heavy metals.
The US Consumer Product Safety Commission (CPSC) or CPSIA:
It approves EVA foam products, particularly children's toys, puzzle mats, and floor tiles. They are tested to make sure that they comply with the Consumer Product Safety Improvement Act.
If you want to use your EVA foam for a longer period of time, you want to keep it in good condition. Then you need to take care of it by following a few tips.
Store them properly: Always store this foam at proper place to protect it from harsh chemicals.
Avoid contact with sharp objects: You should not use excessive force because it can tear or cut the EVA foam.
Always protect them from direct heat: It must be stored in cool and dry places so that it can stay away from direct sunlight.
Clean them regularly: Clean them regularly to keep their surface clean with mild soap or detergent mixed with water.
Yes, EVAfoam is a totally recyclable material, but there are several complications in the process. It is not as straightforward as it is with other materials like paper or metal. Well, you need to know that if you want to recycle EVA foam, then you'll need to provide particular facilities for its handling, specific material properties.
There are some cases in which it may be ground down and reused in production for manufacturing new products. For this purpose, not all the recycling centres accept EVAfoam. There are some local recycling options that you can check for recycling.
EVA foam is a thermoplastic material, which means it can be heated and shaped. After heating, the foam becomes very soft and can be molded into 3D shapes. And when it cools down, it holds its shape permanently.
You can customize this foam for your products according to your demand. Some common shipping methods are
Compression molding: in which foam is pressed into a mold
Encapsulation molding: the foam is formed around the object
Vacuum forming: foam is shaped by using air pressure
In simple words, you can say that you need to heat the foam, shape it, and cool it. And it will be ready to use for packaging parts.
Note: You can customize your EVA sheets into different products like inserts and dividers. If you want them in a gift box, then you can order now.
Can EVA foam be laser cut?
Yes, you can cut EVA foam with a laser. It gives it a clean and detailed cut, but it makes smoke and fumes. So it is better to cut them where the air flow is good.
Can EVA foam be recycled?
Yes, EVA foam can be recycled, but it's not easy. Only special recycling centers can recycle it to make new foam.
Can you cut EVA foam with a hot wire?
Yes, it can be cut with a hot wire. This method works very well for thick foams when you need to give smooth cuts. It is very, it is often used for crafts and cosplays.
Is EVA foam waterproof?
Yes, it is waterproof due to its closed-cell structure. It does not absorb water easily.
Is EVA foam safe to use?
Yes, EVA foam is safe to use. It is very soft, lightweight, and non-toxic. And it is made according to the requirements of safety regulatory authorities.
Is EVA foam flexible or hard?
EVA foam is flexible and soft, and it can bend easily without breaking. And it is wear and tear proof.
What is EVA foam blend?
When manufacturers make an EVA foam blend, they mix EVA with other polymers, rubbers, or additives to change its characteristics. This change in characteristics increases its hardness and durability, and its resistance to heat and flexibility also increases. Moreover, it becomes more chemical and UV-resistant.
Is EVA foam rubber or plastic?
Well, this is a debatable question. But we can say that it is prized for its combination of rubber-like softness and it offers plastic-like toughness. This one property makes it an excellent cushion and shock-absorptive material.
You can buy EVA foam from MyboxPrinting, which is an innovative solution provider in the EVA foam industry. We deliver high-performance above foam that is engineered for providing protection and durability.
Our EVA foams feature a closed-cell and cross-linked structure with excellent chemical resistance and short absorption. They are perfect for long-term applications in the industry. We provide our customers with the structural design from prototyping to final production.
You can customize our foam in different sizes, shapes, and designs to meet your product demand. Due to its versatility and reliability, our EVA foam solutions are suitable for a wide range of applications.
At "MyBoxPrinting", we supply EVA foam in both sheet and roll formats. We offer end-to-end services for this material, and we customize them into different shapes or sizes as per your specific packaging or product requirements.
