Why Plastazote® foam is the go-to choice for military and defence applications

Materials matter in defence

In the military and defence industry, materials are more than just components, they’re a critical factor in reliability, safety, and mission success. From protective packaging to weapon transit systems and aircraft interiors, every material must meet stringent performance, durability, and compliance standards.

Plastazote® foam, a closed-cell, cross-linked polyethylene (PE) foam, has become the material of choice for many such applications. Engineered by Zotefoams, Plastazote offers a balance of strength, lightweight structure, and resilience, qualities that align perfectly with the rigorous demands of military operations.

As an approved distributor and certified fabricator of Zotefoams, Kewell Converters has worked with Plastazote for decades, delivering high-precision, custom-made foam solutions to some of the UK’s most exacting defence and aerospace clients.

What makes Plastazote foam ideal for military use?

1. Lightweight strength

Military-grade materials must strike a balance between strength and weight. Plastazote foam maintains high tensile and tear strength (with tensile strengths of up to 2,376 kPa and tear resistance over 12,000 N/m in some grades) without adding unnecessary bulk. This makes it ideal for:

• Weapons and equipment packaging
• Cargo protection in transit
• Personnel gear such as helmet liners or padding

It reduces load while maintaining durability, critical in mobile or airborne operations.

2. Shock absorption and impact recovery

Impact resilience is a major reason why Plastazote is used for protective and shock-absorbing applications. With a low compression set (as low as 3–7%), the foam returns to its original shape after impact, a critical feature for items subject to rough handling or vibration during transit.

3. Consistent thermal and environmental performance

Materials in defence settings are often exposed to wide temperature variations. Plastazote maintains structural integrity at temperatures up to 125°C, making it suitable for hot climates, engine compartments, or sealed containers. Additionally, it:

• Absorbs less than 2% water
• Resists oils, solvents, and chemicals
• Retains dimensional stability in wet or humid environments

4. Specialised grades for technical roles

Plastazote is available in grades with fire retardant (FR), anti-static, or conductive properties, supporting applications like:

• Explosive-compatible inserts
• ESD-safe electronics packaging
• Flame-retardant aircraft components

Many defence applications rely on these enhanced versions to meet MOD specifications, industry standards like DEF STAN 81-116, or customer-specific compliance needs.

Typical applications of Plastazote in defence and aerospace

Some examples of how Plastazote is used across defence and aerospace sectors include:

• Protective foam for weapons transit cases
• Foam inserts for Euro containers
• Body armour and helmet padding
• Aircraft ejection seat components
• Sensitive electronics packaging
• Foam gaskets, seals, and spacers for vehicles and systems

Its versatile machinability and availability in a wide range of densities (like LD24, LD45, and HD110) mean it can be adapted for everything from lightweight cushioning to structural support.

Materials compliance and supply chain considerations

Beyond performance, traceability and documentation are essential in military procurement. Defence clients often require:

• Full material traceability
• First Article Inspection Reports (FAIRs)
• Certificates of Conformance (CofCs)
• Consistent batch-to-batch quality

This makes supplier choice as important as material selection. Procurement teams, engineers, and quality managers need foam solutions that not only work but comply.

Supplying Plastazote foam: Kewell Converters’ expertise

With over 50 years of experience, Kewell Converters is a JOSCAR-registered foam converter and approved supplier of Zotefoams Plastazote products.

“Plastazote® has a long-standing reputation as the trusted foam solution for defence and aerospace. Its unique combination of lightweight strength, impact resistance, and environmental stability makes it ideal for mission-critical applications where reliability cannot be compromised. We’re proud to support partners like Kewell Converters, who bring decades of expertise in precision converting to deliver tailored solutions that meet the stringent demands of military and defence clients.” Tom Miller, Product Marketing Manager, Zotefoams

Based in Kent, we specialise in producing custom foam for military and defence applications with full in-house CAD design, prototyping, and production.

We work closely with defence primes, MOD suppliers, and aerospace OEMs to deliver:

• Bespoke Plastazote foam components
• Protective packaging for military cargo and electronics
• Precision-cut military-grade foam using CNC, water jet, and routing equipment
• Materials fully traceable and documented to defence standards

A proven material for a demanding sector

Plastazote foam for military use has earned its place as a reliable, high-performance solution for defence environments and one we’ve used for many years at Kewell Converters. Whether it’s being used in a weapon case, a vehicle, or a cockpit, its combination of strength, resilience, and customisability makes it a go-to material for military and aerospace professionals.

If you’re seeking a foam partner with the knowledge, equipment, and compliance capabilities to deliver custom-made military grade foam, Kewell Converters is ready to support your next project.

Ready to enhance your military-grade protection and performance with Plastazote foam?

Get in touch today to explore mission-ready Plastazote foam solutions tailored to your defence requirements.