Lightweight and cost-effective.
Excellent shock absorption and cushioning properties.
Insulating properties help maintain temperature stability.
Can be recycled in some areas.
Less environmentally friendly compared to some other options.
May create static electricity during handling.
Soft and flexible, providing good cushioning and protection.
Resistant to moisture and chemicals.
Can be recycled in some areas.
May be more expensive than EPS foam.
Limited options for recycling compared to other materials.
Soft and resilient, offering excellent shock absorption.
Can be customized for specific applications.
Resistant to compression set and deformation.
Typically more expensive than EPS or PE foam.
May off-gas volatile organic compounds (VOCs) during manufacturing.
Higher density and strength compared to standard PE foam.
Resistant to water, chemicals, and UV radiation.
Excellent shock absorption and cushioning properties.
Higher cost compared to other foam options.
Limited options for recycling.
box liners are less in cost than molded coolers
since the cooler can be made to any size box, you can use whatever box you want including your existing boxes, custom printed boxes, the right strength and size, stock boxes, etc.
because molded coolers will only fit their custom size boxes, you are limited and pay more because of it.
because you can strategically pick the exact size box you need, you don’t waste space which can save a lot on overnight or two day shipments. And a molded cooler has rounded corners and a tapered shape to be able to come out of the mold, which means you can’t fit in as much.
You can have a thicker cooler in the summer and a thinner cooler in the winter, potentially saving you shipping costs!
Insulated shipping liners are flat pieces when shipped or stored. Molded coolers are fully assembled so they take up more space.
Thermal box liners can be made from recycled foam.
Molded coolers have about 5%-8% increased R-value than insulated box liners if the same thickness.
This saves labor time as only the lid has to be put on.
EPS foam, often known as Styrofoam, is recyclable, but recycling options may vary depending on location. Many recycling facilities accept clean EPS foam packaging materials, such as foam blocks, packaging peanuts, and foam cups, for recycling. However, it's essential to check with local recycling programs or facilities to confirm whether they accept EPS foam and if any specific preparation or sorting is required.
PE foam, also known as polyfoam or foam sheeting, is recyclable but may not be as widely accepted for recycling as EPS foam. Some recycling facilities may accept PE foam for recycling, while others may not have the necessary equipment or processes to recycle it efficiently. It's advisable to check with local recycling programs or facilities to determine their policies regarding PE foam recycling.
PU foam, commonly used in furniture cushions, mattresses, and insulation, is less commonly recycled due to its composition and processing requirements. While there are some efforts to recycle PU foam, such as mechanical recycling or chemical recycling processes, these methods may be limited in availability and effectiveness. As a result, PU foam recycling options may be more limited compared to EPS or PE foam.
because you can strategically pick the exact size box you need, you don’t waste space which can save a lot on overnight or two day shipments. And a molded cooler has rounded corners and a tapered shape to be able to come out of the mold, which means you can’t fit in as much.
Use a sharp utility knife or craft knife with a retractable blade.
Mark the cutting line on the Styrofoam using a ruler and pencil.
Hold the Styrofoam firmly in place and carefully cut along the marked line using the knife.
For thicker Styrofoam or more precise cuts, make multiple shallow passes with the knife until you cut through the foam completely, or you can partially cut through the foam and then snap the piece where the cut it.
A hot wire cutter, specifically designed for cutting foam, can provide precise and clean cuts.
Mark the cutting line on the Styrofoam.
Turn on the hot wire cutter and wait for it to heat up
Hold the Styrofoam firmly in place and carefully guide the hot wire cutter along the marked line to cut through the foam. The heat from the wire will melt through the foam, leaving a smooth edge..
A table saw can also be effective for cutting Styrofoam, but beware of the dust.
Position the table saw and yourself properly
Adjust the blade height
Use a push stick or push block
Mark the cutting line on the Styrofoam.
Use a rip fence or miter gauge
Use the blade guard
Maintain control while cutting
A serrated knife, such as a bread knife, can also be used to cut through Styrofoam.
Hold the Styrofoam firmly in place and carefully saw through it using the serrated knife.
This method may not provide as clean or precise cuts as some other methods but can be effective for basic cutting tasks.
If you have access to woodworking tools, such as a band saw or scroll saw, they can be used to cut Styrofoam.
Mark the cutting line on the Styrofoam.
Set up the band saw or scroll saw with a fine-toothed blade suitable for cutting foam.
Hold the Styrofoam firmly in place and carefully guide it through the saw along the marked line to cut through the foam.
Polyurethane coatings are versatile and can be formulated to provide different levels of hardness and flexibility. They can be applied as a spray-on coating and cure rapidly, forming a tough, seamless membrane over the EPS foam surface. They offer good durability and weather resistance, making them suitable for outdoor applications.
Cementitious coatings are composed of cement, sand, and polymers. They are applied as a slurry or mortar and can provide a durable, fire-resistant finish for EPS foam.
Seemingly indestructible, our limestone acrylic aggregate can be hand applied, sprayed and extruded, leaving a thick covering of stone like material that has such a beautiful natural stone look that many people never coat it making it a maintenance free product that lasts indefinitely.
Acrylic coatings are water-based and environmentally friendly. They can be applied as a brush-on or spray-on coating and provide a hard, smooth finish. Acrylic coatings are often used for artistic or decorative applications. Latex paint, even if multiple coats, will not add and significant hardness to the foam, however.
Elastomeric roof coatings are water based so they will not damage EPS foam. It can be brushed on, just like acrylic paint, but it is much thicker. There are different types of elastomeric coatings, so you may have to do some experimenting. The thicker the coating, the better. Elastomeric coatings, while thicker and a bid harder than paint, is still not a hard finish.
Fiberglass coatings consist of a layer of fiberglass mat or fabric embedded in a resin matrix. They offer high strength and impact resistance and can be applied as a laminate over EPS foam surfaces. Polyester resin reacts with EPS foam, so a barrier will need to be applied such as wrapping foil or painting the foam.
Epoxy coatings offer strong adhesion to EPS foam and provide a hard, glossy finish. They are often used for decorative applications or where a high level of chemical and abrasion resistance is required. They are more expensive than polyester fiberglass, but they do not require applying a barrier on the foam as they will not dissolve the foam.
Silicone coatings provide a flexible, waterproof barrier over EPS foam surfaces. They are often used for applications where movement or vibration is expected, such as in building construction or marine applications.
Foam is lightweight compared to traditional building materials such as wood, metal, or concrete. This makes it easier to handle, transport, and install, reducing labor costs and construction time.
Foam can be easily molded, shaped, and carved into virtually any design or pattern, allowing architects and designers to create intricate and customized architectural elements. It can replicate the look of more expensive materials such as stone, wood, or metal, offering a wide range of design possibilities.
Foam is generally less expensive than many other building materials, making it a cost-effective option for architectural applications. It can help reduce overall project costs while still achieving the desired aesthetic and design goals.
Foam architectural elements are often prefabricated off-site, allowing for quick and straightforward installation on-site. This reduces construction time and disruption, leading to faster project completion and reduced labor costs.
Some foam materials, such as Expanded Polystyrene (EPS) or Polyurethane (PU) foam, offer thermal insulation properties, helping to improve energy efficiency and indoor comfort in buildings.
Foam materials can be coated or treated to enhance their durability and resistance to weather, moisture, UV radiation, and pests. Properly protected foam architectural elements can withstand outdoor exposure and maintain their appearance for many years.
Foam materials can provide acoustic insulation and sound absorption properties, helping to reduce noise transmission and improve the acoustics of interior spaces.
Foam can be easily customized to match specific design requirements or replicate historical architectural details. It allows for the creation of unique and visually striking architectural elements that enhance the overall aesthetic appeal of buildings.
Soundproofing aims to prevent the transmission of sound from one space to another or reduce the amount of external noise entering a room. It focuses on blocking or isolating sound waves to maintain privacy and minimize disturbance.
Adding mass: Increasing the density of walls, floors, and ceilings using materials such as heavy drywall, concrete, or mass-loaded vinyl to block sound transmission.
Decoupling: Installing resilient channels, isolation clips, or soundproofing mats to create separation between surfaces and prevent sound vibrations from transferring.
Sealing: Closing gaps, cracks, and openings in walls, windows, and doors to minimize sound leakage.
Adding barriers: Erecting sound barriers such as soundproof curtains, acoustic panels, or double-glazed windows to reduce external noise.
Soundproofing is commonly used in recording studios, home theaters, bedrooms, offices, and commercial spaces to create quiet environments and reduce noise disturbances.
Sound absorption aims to reduce the reverberation or echo within a room by absorbing sound waves, improving acoustics, and enhancing speech intelligibility. It focuses on controlling the reflection of sound within a space.
Installing acoustic panels: Mounting sound-absorbing panels or tiles made from materials such as fiberglass, foam, or fabric on walls, ceilings, or partitions to absorb sound reflections.
Using acoustic ceiling tiles: Installing perforated or textured ceiling tiles with sound-absorbing backing to reduce sound reverberation.
Placing acoustic drapes or curtains: Hanging heavy, dense curtains or drapes made from sound-absorbing materials to reduce sound reflections and dampen noise.
Adding acoustic furniture: Incorporating upholstered furniture, carpets, rugs, or acoustic partitions to absorb sound and reduce reverberation.
Sound absorption is commonly used in auditoriums, conference rooms, classrooms, restaurants, theaters, and recording studios to improve sound quality, minimize echoes, and create a more comfortable listening environment.
