Polystyrene Foam

One of the world's most popular packing and insulating materials, polystyrene foam is a practical material that many people encounter on a daily basis.

Qualities and Manufacturing Process

Expanded polystyrene is made from pre-expanded polystyrene beads that are heated, aged, inserted into block shaped molds, and then cooled. The result is a strong, rigid, and lightweight material that has many advantageous physical properties. Polystyrene is very resistant to mold, bacteria, and mildew, does not attract insects, and is almost completely resistant to moisture and water vapor. It is also an excellent insulator due to its high thermal resistance (R-value).

The final density of an EPS block is controlled by the extent that the polystyrene beads are allowed to expand before being molded to shape. While the various densities of polystyrene share similar properties, higher densities have better heat resistance, lower permeability, and can withstand greater forces before deforming or breaking. All densities of EPS are commonly used as packaging materials, residential insulation, and marine flotation materials. 1LB polystyrene can be used for toys, arts, and crafts; 2LB polystyrene is often used to make hot tub covers and decorative foam signs; and 3LB polystyrene is frequently used for industrial insulation and construction.

Our Polystyrene Inventory

Foam Factory carries sheets of expanded polystyrene in three different densities: 1LB, 2LB, and 3LB.

Our polystyrene foam sheets are available for immediate order in a standard size of 24”x48” and thicknesses from 1” to 8” as either a single sheet or a budget-friendly 4-pack. We can accommodate custom orders of sizes up to 48”x96” and thicknesses up to 32”. Further fabrication, such as precision shapes and contours, can also be accomplished via custom-cutting on either our waterjet or hot-wire machines.

At Foam Factory Inc., we pride ourselves on delivering great products at affordable prices. If you have any questions or concerns while shopping with us, please Contact Us, and a member of our team would be happy to assist you further.

What is polystyrene foam?

Polystyrene is a synthetic polymer that has thermoplastic properties. It is derived from the petroleum-based monomer known as styrene. The end result is a lightweight, but sturdy, closed-cell foam. Polystyrene is ideal for a wide range of applications, including: construction, modeling, insulation and more.

Is polystyrene foam the same as Styrofoam?

Contrary to popular belief, Styrofoam and Polystyrene are not necessarily the same, despite being made using the same monomer, styrene. Styrofoam, which is blue in color, is made from extruded polystyrene (XPS), while Polystyrene (EPS), which is white in color, is made from expanded polystyrene. The true main difference between these two materials is the process by which they are created.

What is polystyrene foam used for?

Polystyrene foam is most commonly used for construction, insulation and packaging. For this reason, you will often see it used to make coolers, hot tub covers and in packages with specific needs. Due to its resistance against moisture, mildew and rot, it is also good for applications where water vapors may be present.

Is polystyrene foam toxic?

Polystyrene foam has been carefully studied for decades to determine safety. Like many products, in massive amounts, polystyrene can carry a certain level of toxicity. Styrene, however, is found in small amounts throughout nature; it can even be found in the foods that we eat. Polystyrene foam is not toxic when used appropriately. In fact, polystyrene is often used in food packaging. The FDA has deemed it a safe material for this purpose, which speaks to its safety.

Is polystyrene safe for insulation?

Thanks to the closed-cell nature and the higher R-Value, polystyrene makes for a great insulator. As for safety, there has been no hard evidence to suggest that it is not a safe, viable choice for insulation.

Is polystyrene a fire hazard?

Polystyrene is typically not considered a fire hazard, but that doesn't mean that it is fireproof. Most materials will eventually start to burn when exposed to fire, unless fire retardant additives or coatings have been applied. In general, polystyrene does not pose the threat of being more combustible than other materials when exposed to flame or extreme heat.