Expanded polypropylene or EPP is a highly durable injection moulding foam material.

During the moulding process polypropylene resin is subject to pressure, high temperatures and CO2 in an autoclave; this inflates the material into small foam pellets or beads. Once expanded, the tiny foam beads are then injected into a rectangular block tool where steam is forced through under pressure.  The moulded polypropylene blocks are released from the tool and then have to undergo curing in a large oven for 24 to 48 hours to allow for shrinkage.

We have a variety of different sizes EPP capable block tools that we use to mould both high and low densities. Our speciality Polypropylene Block can also be moulded in some really bright and vibrant colours to give visual appeal to your projects.

Our EPP block can be moulded in the following measurement and cut to size:


Max Dimensions


1000 x 600 x 150 mm


1200 x 1000 x 200 mm


1385 x 1000 x 200 mm

All of our speciality block grades are moulded from virgin ARPRO® EPP bead.

Our EPP block offers:

  • A range of densities and sizes to suit you
  • Superior properties compared to other foam
  • Colours for improved design and appeal
  • Strength, quality & repeat shock performance

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

These services are available upon request:

Send us an email: foam.products@dssmith.eu
Write an enquiry: Enquiry Form

You can even buy our block online, take a look at our Online shop.