PU Foam vs PE Foam: What's the Difference?

When choosing foam for a protective case, it's important to understand that not all foam materials offer the same level of protection, durability, practicality or presentation.

Two of the most common types of foam used in protective cases are Polyurethane (PU) foam and Polyethylene (PE) foam. Each material has unique characteristics that make it suitable for different applications, from DIY equipment protection through to precision CNC-machined inserts for valuable tools and instruments.

In this guide, we'll explain the differences between PU and PE foam, where each is typically used, and how to choose the right solution for your equipment.

What Is Polyurethane (PU) Foam?

Polyurethane foam, often referred to as PU foam or open cell foam, is a soft, lightweight, medium density foam commonly used in protective case interiors and general packaging applications.

Its cushioning properties make it an excellent choice for protecting delicate items from knocks and vibration during transport and storage.

Benefits of PU Foam

• Lightweight and economical
• Excellent shock absorption
• Easy to customise
• Suitable for a wide range of equipment
• Available in various formats and thicknesses

Because PU foam is softer than PE foam, it is particularly well suited to lighter or more delicate equipment.

Cubed and Pick & Pluck Foam

One of the most popular forms of PU foam is cubed foam, also known as pick and pluck foam.

The foam is pre-scored into small cubes that can be removed by hand to create a custom-shaped cavity for your equipment.

Advantages of Cubed Foam

• No specialist tools required
• Quick and easy to customise
• Cost-effective solution
• Ideal for one-off applications
• Great for creating custom layouts

Pick and pluck foam is commonly used to protect:

• Cameras and lenses
• Drones
• Test equipment
• Electronics
• Hobby equipment
• Small tools and accessories

For users looking for a simple custom foam solution without the cost of bespoke machining, pick and pluck foam is often the ideal choice. For more information about cubed foam and how to use it, click here.

Egg Foam

Egg foam, sometimes called egg crate foam, egg box foam, or convoluted foam, is another popular PU foam product.

Its distinctive ridged profile provides gentle cushioning from above when a case is closed.

Benefits of Egg Crate Foam

• Protects equipment from movement
• Helps absorb vibration and impact
• Lightweight and affordable
• Ideal for case lids

Egg crate foam is frequently paired with a foam base insert to provide all-round protection during transport.

Plain Foam Sheets

Plain PU foam sheets offer a versatile solution for a variety of applications.

They can be cut to size, layered, or combined with other foam products to create protective packaging and storage solutions.

Many customers use plain foam sheets to:

• Line cases and boxes
• Add additional cushioning
• Create simple custom inserts
• Replace worn foam in existing case

What Is Polyethylene (PE) Foam?

Benefits of PE Foam

• High durability
• Excellent impact resistance
• Water-resistant closed-cell structure
• Long service life
• Suitable for heavier equipment
• Professional appearance

PE foam is commonly chosen for equipment that is transported frequently or requires a precise, repeatable fit.

CNC Machined PE Foam Inserts

PE foam is the preferred material for our bespoke CNC foam inserts. Using CNC machining, we create highly accurate cut-outs tailored to the exact dimensions of your tools, instruments or equipment. 

This creates a professional insert that:

• Holds equipment securely in place
• Reduces the risk of damage during transport
• Improves organisation
• Makes missing items easy to identify
• Creates a premium presentation

PE foam inserts are widely used for:

• Engineering tools
• Measuring equipment
• Medical devices
• Electrical test equipment
• Calibration instruments
• Flight cases
• Demonstration and presentation kits

If you're looking for a precision-engineered solution, PE foam is often the best choice. 

PU Foam vs PE Foam: What's the Difference?

Which Foam Should You Choose?

The best foam depends on your application.

Choose PU foam if you need:

• A cost-effective solution
• DIY customisation
• Pick and pluck inserts
• Lid foam
• General protective cushioning

Choose PE foam if you need:

• A professional custom insert
• Long-term durability
• Protection for valuable equipment
• CNC-machined precision
• A premium presentation

Need a Custom Foam Solution?

Whether you need replacement foam for an existing case, pick and pluck foam for a DIY project, or a bespoke CNC-machined insert designed around your equipment, our team can help.

For precision-cut foam inserts, we typically use high-density PE foam to create durable, professional solutions tailored to your exact requirements.

Explore our custom CNC foam insert service to learn how we can create a foam solution specifically for your equipment*.

*Minimum order quantity of 10 applies.