EVA Foam vs PE Foam: Custom Case Insert Comparison 2026

Foam insert material comparison. Density, water resistance, cost, applications for B2B cases.

Custom foam inserts are critical for protective case value. EVA (Ethylene-Vinyl Acetate) and PE (Polyethylene) are the two most common materials. This guide compares 10 dimensions to help B2B buyers select the right foam.

Comparison Table

PropertyEVA Foam (Closed-Cell)PE Foam (Polyethylene)Best For
Density (kg/m³)30-200 (typical 50-100)25-80 (typical 35-50)EVA: high density
Water Absorption< 1% (closed-cell)1-3% (cross-linked: < 1%)Both: closed-cell low
Compression Set (50% recover)Good (5-10% permanent)Excellent (2-5% permanent)PE: long-term shape
Tear StrengthFair (1.5-3.0 kN/m)Good (3-5 kN/m)PE: rough handling
Temperature Range-40 to +80°C-50 to +90°CPE: wider range
Chemical ResistanceGood (acids, alkalis)Excellent (oils, fuels)PE: oils/fuels
Custom Cut Cost (per case)$15-30 (laser)$10-20 (water jet)PE: 25% cheaper
Density Cost (per kg)$8-15$5-10PE: lower cost
Color OptionsBlack, gray, blue, customBlack, white, customSimilar
Eco-FriendlinessRecyclable, ROHS compliantRecyclable, ROHS compliantSimilar
Best ApplicationsCamera, medical, electronicsTools, military, industrialMatch use

Why Choose KeXinMaterials

Frequently Asked Questions

Is EVA or PE foam better for custom case inserts?

Depends on application. EVA is better for: camera, medical, electronics (higher density, custom laser-cut precision, aesthetic). PE is better for: tools, military, industrial (better tear strength, lower cost, wider temperature range). For most B2B cases under 50L with electronics, EVA is the default. For tools/military/heavy equipment, PE is better. Many premium cases use multi-layer foam: PE base layer + EVA top layer for best of both.

How much does custom foam insert cost?

Pluck foam (DIY): $5-15 per case, no setup fee. CNC-cut foam (standard shapes): $30-80 per case + $50-200 setup fee. CNC-cut foam (complex shapes): $80-200 per case + $200-500 setup fee. Custom molded foam (high precision): $150-400 per case + $1,000-3,000 setup fee. For orders 1,000+ units, setup fees amortize. PE foam is 20-30% cheaper than EVA. Lead time: 7-15 days for custom cut, 30 days for molded.