Moulded Foam Blocks

Our Polystyrene Block website offers a range of Expanded Polystyrene (EPS) and Expanded Polypropylene (EPP) Blocks.

Our 2 specialist block moulding facilities based in the UK:

  • Northampton (moulding EPP)
  • Livingston, Scotland (moulding EPS)

Polystyrene Block

The largest one-piece polystyrene blocks we supply is 2500 x 1250 x 1000mm. Blocks are available from Standard Density to Ultra High Density in both white and graphite grey (on request).

Our Fire Retardant (FRA) EPS block is available in the following grades:


Density (grams/litre)

Max dimensions



2500 x 1250 x 1000mm



2500 x 1250 x 1000mm



2500 x 1250 x 1000mm



2500 x 1250 x 1000mm

Please contact us to discuss your needs further or if you require:

  • Additional cutting (extra cost incurred)
  • Bulk quantities (full lorry loads)

EPS block is produced using a similar process to moulded parts, but on a much larger scale so the finished blocks tend to be much larger. Block can then be hot wire cut or hand scooped.

Our block is widely used in the construction industry for wall and floor insulation. It is also used for packaging where parts are very simple shapes can be hot wire cut to protect corners and edges. As with moulded EPS, cut parts are fully recyclable.

Our white polystyrene block is manufactured at our facility in Livingston where they have specialist cutting equipment if you require specific dimensions.

Applications for Expanded Polystyrene blocks:

  • Construction and civil engineering
  • Theatre, Television and Film production
  • Model making, arts and crafts
  • Exhibition, Display and Design Companies
  • Sculpting

Polypropylene Block

Expanded Polypropylene or EPP is a highly durable impact energy management material used widely for impact protection an cushioning in the automotive sector.

We have a range of EPP capable block tools that we use to mould both high and low densities.

Standard sizes and densities below:


Max Dimensions

Densities available (grams/litre)


1385 x 1000 x 105mm

40, 60, 90


1385 x 1000 x 155mm



1385 x 1000 x 200mm

30, 40, 45, 50, 60, 80, 90


1110 x 1100 x 9-50mm

Made to order (min quantity)

(All block grades are moulded from virgin ARPRO® EPP bead.)

We hold a small stock of black EPP blocks available to order online. Larger quantities are made to order with a 3 to 4 week lead time (a minimum order quantity applies).

EPP material offers:

  • Superior properties compared to other foams
  • Strength, quality & repeat shock performance

If you have a specific project you need our assistance with we can offer additional services like design, cutting, sampling and CNC milling.

Our EPP blocks are typically used for:

  • Automotive prototypes
  • Seat foams
  • Side impact protection
  • Packaging prototyping
  • Remote controlled model aircrafts


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