Did you know that you can design your own products at lower costs by using large blocks of expanded polystyrene (EPS), expanded polypropylene (EPP) or expanded polyethylene (EPE)? There are many benefits to be had from using these materials. Let's look at a few!


5 Advantages of Expanded Plastic Blocks

1. Applicable for any Sector

Expanded plastics are found everywhere around us, in various forms and functions. They’re even critical in many industries. Large blocks, or the end products built from them, can be found in roads and viaducts, home insulation, and more. They can even be found under skating rinks, under floating docks, for archery and for pools and spas.

2. Prototype Design

It’s possible to make prototypes to ensure that the product meets your needs. This way, you can confirm that your project requirements and your expectations are met. Our expertise and technology allow us to manufacture very low or very high density EPP blocks, which are ideal for your prototype designs.

3. Product Customization

Large blocks of expanded polystyrene (EPS), expanded polypropylene (EPP) and expanded polyethylene (EPE) allow customized products fabrication. You can get shapes at the desired density and size, made with the required material, desired manufacturing process, and you can even sometimes chose the material color! Depending on your needs, the blocks can be hot-wire cut, or using your own cutting dies. When we mention customized products, we mean it: you can even laminate your parts. The options are endless!


Polyform - Hot Wire Cut

4. Cost Reduction

The ultimate goal is to make a product that meets all your needs, but at a reasonable cost. On the other hand, you also want to stand out from your competitors while ensuring your customers’ loyalty. However, a new product or a custom part can generate significant costs. Using large blocks can help you develop your product while reducing your investment.

5. Support from Beginning to End

Are you ready to get started? We can go through the whole process with you. We can develop technical drawings to insure the final product will meet your expectations. Once you approve the drawings, our professionals will work hand in hand with you to build your prototype. Adjustments can then be made so the production meets your needs. If there are any cutting scraps from EPS or EPP, we also offer a recycling service.


Polyform - Large foam blocks


Differences between EPS, EPP and EPE

Expanded plastics have one thing in common: they are made of 98% air and only 2% material. However, each material has unique properties. Expanded polystyrene is lightweight and is easy to mold and hot wire cut, making it the perfect material for various products design. It has great insulating properties and offers many possibilities. EPS can be used for complex projects, as well as roads planning as light embankments. 

Showing all same properties as EPS, expanded polypropylene (EPP) is also well known for its shape memory. This feature allows it to maintain its structure without breaking after an impact. It offers great shock and temperature variation resistance.

As for expanded polyethylene (EPE) it is very similar to EPP, only with more elasticity. This is why it is often used for products with critical flexibility and impact resistance requirements.


In many ways, large blocks make interesting options. Don’t hesitate to contact our representatives to discuss your project ideas; we are always opened for new challenges!

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