Thermoforming of EVA and Evazote Foams

Overview

EVA (Ethylene-Vinyl Acetate) and Evazote® foams are versatile closed-cell materials known for their excellent flexibility, impact resistance, and durability.
One of their unique advantages is their ability to be thermoformed — a process that uses heat and pressure to shape foam into precise three-dimensional forms.

At PJ Bowers, while we don’t provide thermoforming services directly, we supply a wide range of thermoformable foams suitable for customers who wish to pursue this process for specialised applications.

What is Thermoforming?

What is Electrolysis and galvanic corrosion?

Galvanic Corrosion is the corrosion that occurs when two dissimilar metals are used together in a structure and exposed to an electrolyte (salt water, chemical, petrol) and the less noble of the 2 metals will corrode. For example; aluminum sheet with steel fasteners on a boat. Some pairings of metals are more at risk of . Check a galvanic series or chart.

Electrolysis is the acceleration of the galvanic corrosion when electricity is introduced to the metals in question. Connected by an , the less metal experiences accelerated galvanic corrosion.

while both processes involve metals and electrolytes, their dependence on an external voltage source distinguishes them.

Thermoforming is a manufacturing process where foam sheets are heated until pliable, then formed over a mould using vacuum, compression, or mechanical pressure.
Once cooled, the foam retains its new shape, resulting in lightweight and durable components.

Common stages include:
Heating – Foam is gently heated to its forming temperature (typically 100–130°C for EVA and Evazote foams).
Forming – The softened foam is pressed or vacuum-formed onto a mould.
Cooling – The foam cools and solidifies into the desired shape.
Trimming & finishing – Excess material is removed, and edges are smoothed.

Why Thermoform EVA and Evazote Foams?

Thermoforming offers design flexibility while maintaining the core mechanical and cushioning properties of the foam.

Lightweight & Resilient

Excellent strength-to-weight ratio for protective or structural components.

Closed-cell structure

Waterproof and resistant to most chemicals.

Elastic memory

Retains shape after impact or compression.

Thermal formability

Allows seamless, smooth contours and tailored fit to complex geometries.

Durability

Long-lasting even in demanding industrial or outdoor settings.

Applications of Thermoformed Foams

Thermoformed EVA and Evazote foams are used across a wide range of industries:

• Protective cases and inserts – Custom-moulded packaging for tools, electronics, or instruments.
• Sports and medical gear – Helmet liners, knee pads, orthotics, and prosthetics.
• Automotive and marine interiors – Shaped insulation, gaskets, and padding.
• Animal and veterinary products – Comfort pads, saddle inserts, or shaped supports.
• Display and retail products – Smooth, contoured presentation forms or trays.

Thermoformable Foams from PJ Bowers

We supply a range of EVA and cross-linked polyolefin foams suitable for thermoforming:

• EVA Foams – Soft, flexible, and available in multiple densities and colours.
• Evazote® Foams – Premium nitrogen-expanded EVA with fine cell structure and high resilience.
• Zotefoams® Range – Lightweight, uniform, and easily thermoformed using heat or vacuum moulding techniques.

Important Considerations

When working with thermoformable foams:

• Use controlled, even heating to prevent scorching or shrinkage.
• Employ temperature-calibrated moulds and gentle vacuum pressure.
• Allow sufficient cooling time before handling to retain shape stability.
• Always test on small samples to determine the ideal forming conditions for your specific foam grade.

Summary

Thermoforming enables designers and manufacturers to unlock the full potential of EVA and Evazote foams — creating precise, lightweight, and functional components.
Although PJ Bowers does not perform thermoforming in-house, we’re proud to supply the high-quality foam materials used in these applications across automotive, marine, packaging, and industrial markets.