Foam Padding

[Gear Dynamics]

I'm looking for input on foam padding. What do you guys use? I'm trying to optimize my materials for my products in order to see if there is a better solution than what I'm currently using. Right now I'm using a product called EV50 (Product Page) in sheets that are only 1/8" thick, but I need the foam to be more resistant to compression and rigid, especially over time. I'd like to avoid going to a thicker material, as this will take away from the concept of the gear. 

[SunriseTacticalGear]

This is what I'm currently using for tripod bags as a padding between the inner liner and outer shell.
Scott
https://www.jennisfabrics.com/jennis-web-core/productProfile.jef?prdCode=00006972&invType=REG

[Fouinard]

I'm using Plastazote 1 cm (~3/8") for straps and pack backpanels with a density of 33kg/m3 density, if I remember correctly. Also 3 mm (~1/8") which is really thin for some small pouches and 5 mm (~3/16") for chestrig straps/panel padding and small pack backpanels with a 45kg/m3 density.

I believe EV is Evazote, I used to use that in 8 mm (~5/16") thickness it has a neoprene feeling but I think it's too soft/"smooth", Plastazote tends to better get back to it's original state after being compressed.

What do you want to use it for?

[Gear Dynamics]

I'm using the foam for padding in my rigs and harnesses. I want the optimal foam. Right now the EV50 is pretty good, better when laminated to at least one layer of Cordura, but I think it could be better. Time for more samples I guess...

[jw9673]

I'm not a production shop, but only a hobbyist. In my search I found this. I'm not sure of your wholesale cost but the tech specs on this show it to be a great substitute.

[Gear Dynamics]

What did you find?

[jw9673]

Sorry the link didn't stick.. I'll try again.
http://store.acor.com/acor-p-cell-eva-foam/

[Martial Concepts]

Looks promising. How does it behave in hot/cold temperature?  I don't want something that turns steel hard in freezing temperatures.

[jw9673]

I'm sure its fine in hot temps as its for orthotic shoe inserts.. as for cold, I will let you know when I order some for a project.. I'll have to throw a piece in the freezer though, not many blizzards here in central FL..

[Martial Concepts]

Did you ever order the foam and try it out?

[Disturbed]

http://www.ultralon.co.nz/

That's who I use for my foam, I basically talk to them about the application I need it for and they steer me in the direction of the right foam.  A PE foam I use a lot they developed for sleeping mats for the NZDF, its specced to stay flexible at -10 celcius which I've found useful for pack straps.  I can also get them to laminate foams for me and I have some PE35/EV60 which are fuzed so less chance of a separation from gluing.

[BOgear]

I use both 5mm and 10mm foam for our products. It is a PU/EVA blend and works well for most of our applications. We've optimised all of our products to use this material rather than having multiple foams (can't get away from needing two thicknesses). It is a 45kg density. I have experimented with less dense (25-30kg density) but these compress out over time and don't give long lasting results. For 1/8inch / 3mm you would probably be better with a heavier density (but flipside is heavier weight).

Full tech specifications, and supplier link (in Australia): http://www.3hfoam.com.au/pdf/WB45.pdf
(Also mentions operating temperature, but I've only personally tested it between 10 - 45 degrees Celsius.) FYI, WB4510 is the code (WB is the blend, 45 is the density, 10 is the thickness)

Supplier stocks 10mm and can split it to thinner thicknesses, or bond/fuze (like @disturbed's supplier) it together for a thicker build. Supplier also does some basic pressed moulded products (think swimming kickboards) should this interest.

Hope this helps!

[Gear Dynamics]

Thanks guys. The replies are excellent and I'll post results if I come across a good solution.

[762Tactical]

I use the 1/4" Mini-cell or Cross-Linked Polyethylene for most everything. It's really nice for shoulder pads/padded belts.  http://www.thefoamfactory.com/closedcellfoam/cross-linked-polyethylene-foam.html Free shipping for orders over $75 but I typically order 5 to 8 sheets at a time.