Particle Foam Moulding

Lightweight, Strong, and Versatile

In the particle foaming process, products are created using thermoplastic foam beads that are expanded and fused together in a heated mould.  Products created using particle foams are distinguished by their extremely lightweight, high dimensional accuracy and strong 3D–shaped construction that can take nearly any form.  In addition to that, particle foam products have high energy adsorption at impact, low thermal conductivity and acoustical insulation. Particle foam products are also very cost-effective due to their efficient use of materials during manufacturing. In Armstrong, we provide customers with complete turnkey solutions for particle foam manufacturing from the initial design phase to production.  With our extensive experience and know-how, we assure customers of the best possible results.

Particle Foam Moulding

Our Capabilities

Armstrong has been providing high-quality particle foam parts to our customers for over a decade. We have a long-standing reputation in the industry for being able to deliver the best solutions to our customers, and they trust our abilities to fulfill our commitments.
Particle Foam Moulding Capabilities
  • Manufacturing
    • Production of moulded parts up to a size of 1,200 mm x 1,800 mm and density from 20 – 200 kg/m3
    • Moulding of dual-density sections within a single part for different functions
  • Insert Moulding: Production of particle foam parts with plastic inserts, metal brackets and wires moulded directly into the parts for sub-assemblies
  • Lamination & Coating: Coating and lamination of a variety of materials onto particle foam parts for functional and aesthetic purposes


Particle foam consists of foam beads which can be made from various thermoplastics. The most commonly used particle foam materials are Expanded Polypropylene (EPP), Expanded Polystyrene (EPS), Expanded polyethylene (EPE) and Expanded Thermoplastic Polyurethane (E-TPU). Depending on the applications, Armstrong is able to recommend the most suitable particle foam materials.

Shock Absorption / Protection

Weight Reduction