Plastazote Foams
Information about the material properties of Zotefoams' Plastazote series and where to buy them.
Zotefoams
Zotefoams is a global foam manufacturer, one of the largest in the world. They produce many blends of foam under different brand names. For our needs, specifically the Plastazote line under the AZOTE brand is the most accessible and appropriate, but we will still provide an overview of the others for deeper context.
Note: You will not be able to get these directly from Zotefoams, but their site is still a great source of information on their product lines.
AZOTE
Links go to Zotefoams' product pages, where you can find even more information.
Evazote (ethylene co-polymer foams, e.g. EVA based foams)
"Evazote closed cell crosslinked ethylene copolymer block foam has densities ranging from 30kg/m³ to 50kg/m3."
Plastazote (PE foams and blends)
"Plastazote is a lightweight, crosslinked low-density polyethylene (LDPE) block foam, with densities ranging from 15kg/m³ – to 115kg/m3."
Supazote (a specific cross-linked ethylene co-polymer)
"Supazote is a lightweight, crosslinked closed cell ethylene copolymer foam recommended for “soft-touch” applications where a covering is not required."
ZOTEK
Zotek foams are based on higher end polymers, such as polyvinylidene fluoride (PVDF) and thermoplastic elastomers (TPE), and are engineered for more demanding purposes. Lightweight cushioning for aerospace seating and impact padding for full contact sports and military gear are where you would generally see these used. Some foams from the product lines under this brand are liable to be quite nice for our needs, but are not going to be as accessible or cost effective.
ECOZOTE
Zotefoams' "eco-friendly" lines of foam. Some come with up to 30% recycled material used to produce them. Not chemically blown. PE, PP, and TPU foams are available under this brand, with some essentially just being the eco-version of foams from other lines, such as LDR18 being an equivalent to LD18 from the Plastazote line.
Plastazote
There are a handful of foams from this product line, and one that is a proprietary blend from one of the suppliers of these foams, that are particularly relevant to our needs. This is also the line of foams that "Aethertube" reblades that have been sold by various vendors comes from.
While "Aethertube" has been potentially used to label 3 different foams over the years from various vendors, LD15 is the foam that would have been the lightest of those. This name should not be used when discussing this foam except as a way to give context to someone that may already know about it by that name, as it obscures the actual product information.
LD15
0.9-1
15
223
999
6
47
LD18
1.1-1.15
18
299
1317
4
50
LD24
1.5
24
328
1254
4
50
LD29
1.8
29
337
1760
3
54
WZ30
1.9
30
405
677
3
56
The foams in the table above have all been tested. LD15-LD29 are all wonderful striking surface foams. They start off at a similar stiffness (to hand-feel levels of pressure) and quickly break in to their long term softness. WZ30 is much stiffer out the door and, while still likely viable for striking foam long term, it may be best relegated to things like making shields, core boxes, and pommels.
LD15 and LD18 are "must skin" foams in that, if you don't skin them fully with Tyvec (or some equivalent), you will see tears at the ends of your stab tip support tape within a few days of use and the foam will break down much faster. It is still a good idea to skin the other foams, but it is not nearly as critical as tensile strength increases.
For comparison, Volara 2A has a tensile strength of 476 and a shore hardness (OO) of 51.
Sourcing Plastazote Foams
Anyone selling "Aethertube" is most likely supplying LD15, but unless they'll tell you that for sure, you'll never really know. You can weigh what you get and do some math, but that's about as close as you'd get.
The Whackerdashery
For small volumes and reblades, I would be remiss to not recommend myself as a source.
LD15
omni reblades (24" and 48"), quarter sheets (24x48), and eighth sheets (24x24)
WZ30
quarter sheets (24x48), eighth sheets (24x24), and 30x30 shield blanks
You can find more information at the business site: https://www.whackerdashery.com
Worldwide Foam
The best vendor for sourcing these foams in the US is Worldwide Foam. They have a minimum order quantity (MOQ) requirement of $1000 that you can waive by paying a fee ($150). You will get the foam as "buns", which are large 48"x76" (more like 50"x78") sheets at the requested thickness, delivered on a double pallet. They can deliver to residential addresses this way, but you may need to interact with the local company doing the delivery so they know not to use a full sized trailer for the delivery and that you don't have a loading dock.
You will need to contact them requesting a quote using an email with a business domain (they automatically block gmail addresses, for instance). They will put you through a process to add you to their systems, collect payment information, and establish if you are tax exempt. Payment was accepted via a wire transfer, which may incur a fee from your bank that will add to your costs.
If making half-tube reblades, it is most cost efficient to get the foam at the "default" 2" thickness and find a use for the offcuts, but you can get it thicker or thinner based on your preference and cost-tolerance.
They are very responsive and can get you moving on orders quickly, but when I first reached out, I was actually pushed away by the rep that responded with the suggestion that I would be too low volume to order from them. If you get a response like this, just be assertive about knowing that you will either hit MOQ or be willing to pay the fee and that you would still like to order. When I reached out again with a direct request for a specific quantity of a specific foam instead of as an exploratory inquiry, my order was finalized within a week. I honestly wouldn't even bother reaching out to any other supplier if you are US based.
Worldwide Foam is also the only top-level source for WZ30 and WZ45 (they have customers that supply these foams after getting it from Worldwide Foam), as they are their proprietary blends.
Their website is: https://worldwidefoam.com/
Wisconsin Foam Products
They source from Worldwide Foam, so you'll be waiting for them to middleman communication and quote requests, while also paying double freight to have it shipped to them, and then to you. They were frustrating to work with, getting multiple quotes wrong with extra products and/or missing information, and were blaming Worldwide Foam for communication delays that lasted weeks on end.
They are a reputable business and have a good track record to my understanding, while also being one of the more responsive suppliers I've interacted with, but I would only reach out to them if you want to have the foam processed/shaped into the final product before it gets to you instead of getting sheets you need to cut and shape yourself.
Polyformes
A converter from England. Responsive and good prices, will accept emails from gmail accounts, and gives informative quotes. The only downside is that they are in Europe and that international shipping and duties/taxes will raise costs to be similar to or worse than what you would see with Wisconsin Foam Products' double-freight situation.
Amcon Foam
Very helpful and informative sales reps, when you can get them on the line and to follow up with you. I had a half hour conversation with one of their reps when they called me instead of emailing to respond to my initial inquiry, only for that same guy to never follow up with me. They have emails sent checking in on potential customers that go out on behalf of their vice president, one of which I responded to asking if I'd ever hear back and name dropping the representative, which finally got me another call where he told me they source from Worldwide Foam and Sekisui Voltek. Unfortunately, he again stopped being responsive immediately and never followed up.
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