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MPP Foam is a supercritical foamed polypropylene material produced using supercritical CO₂ physical foaming technology.
By introducing a large number of fine and uniform microcells into a polypropylene matrix, MPP combines the inherent advantages of PP with the lightweight, cushioning and thermal insulation characteristics of microcellular foam.
Compared with conventional PP materials, MPP significantly reduces material density while maintaining high mechanical strength and dimensional stability. Its closed-cell structure also provides good water resistance and thermal insulation.
MPP is particularly suitable for applications where weight reduction, compression support, impact protection, thermal insulation, flame resistance and environmental compliance are required.
Typical applications include:
EV battery components
Battery module cushioning
Cooling plate support
5G communication equipment
Antenna covers and radomes
Cold-chain transportation
Protective packaging
Aerospace and military equipment
Lightweight structural components
Model and recreational products
XYFOAMS currently provides MPP grades from approximately 40–95 kg/m³, with different density and compression-performance levels available for specific application requirements.
MPP uses a microcellular structure to significantly reduce material weight while maintaining the mechanical strength of polypropylene.
The high strength-to-weight ratio makes MPP suitable for lightweight structural components, transportation equipment, battery components and protective products.
The current MP series covers densities from approximately 40 kg/m³ to 95 kg/m³, allowing engineers to balance weight reduction and mechanical support.
MPP provides controllable compression performance across different grades.
The material can provide high compression stress at relatively low density, making it suitable for long-term cushioning and structural support.
This is particularly valuable in EV battery applications where the material needs to maintain support under continuous mechanical loading and cell expansion.
Supercritical CO₂ foaming produces a fine and relatively uniform microcellular structure.
The controlled cell structure contributes to:
Lightweight performance
Compression resistance
Impact absorption
Thermal insulation
Dimensional stability
Surface quality
The uniform microcell structure is also beneficial for precision converting and customized component production.
MPP can absorb and dissipate mechanical impact through deformation of its cellular structure.
It is suitable for battery cushioning, protective packaging, transportation equipment, military protection and other applications where impact resistance is required.
The microcellular structure reduces heat transfer through the material.
MPP provides thermal conductivity of ≤0.05 W/m·K, with typical values around 0.042–0.044 W/m·K depending on grade.
This makes MPP suitable for cold-chain transportation, battery thermal management and lightweight insulation structures.
MPP has a closed-cell structure and an integral PP surface, providing good resistance to water and moisture.
This makes it suitable for applications exposed to humidity, condensation or outdoor environments.
Typical applications include:
Cold-chain panels
Protective packaging
Transportation components
Outdoor communication equipment
As a polypropylene-based material, MPP provides good resistance to many common chemicals, oils and industrial substances.
This makes it suitable for demanding industrial and transportation environments.
MPP grades can achieve UL94 HF-1 flame-retardant performance.
This makes the material suitable for automotive, battery, communication and other applications where flame resistance is required.
MPP is designed for applications requiring stable performance across a relatively wide temperature range.
The current technical information specifies a long-term service temperature of approximately 110°C, with application data also indicating performance from approximately -40°C to 110°C for communication applications.
MPP is produced through physical supercritical foaming rather than conventional chemical foaming.
The material complies with relevant environmental requirements including:
RoHS
REACH
ELV
VOC requirements
The non-crosslinked PP structure also provides recyclability and supports material recovery at the end of service life.
Unlike crosslinked PP foams, MPP is a non-crosslinked polypropylene foam.
This provides an important advantage for recycling and circular-material strategies while maintaining the lightweight and mechanical benefits of foam.
MPP is particularly suitable for battery components requiring high compression support, lightweight construction and dimensional stability.
Typical applications include:
Prismatic cell spacers
Cell-to-cell cushioning
Module side pads
Battery module cushioning
Cooling plate support
Battery pack bottom support
Structural cushioning
For prismatic battery cells and module side pads, MP20 and MP25 are recommended in the current application data. Their relatively low density helps reduce weight and occupied space while providing cushioning between components.
For battery pack bottom support and cooling plate support, MP10 and MP15 provide higher compression support and are recommended for applications requiring more sustained mechanical support.
MPP's lightweight structure, low dielectric characteristics and low dielectric loss make it suitable for communication equipment and antenna-related applications.
Typical applications include:
5G microwave radomes
Antenna covers
Communication equipment housings
Low-dielectric structural components
MPP's fine microcellular structure provides low dielectric and low-loss characteristics, with application data covering frequencies including approximately 4–80 GHz and E-band applications.
MPP combines:
Low Density + Thermal Insulation + Water Resistance + Structural Strength
This makes it suitable for lightweight cold-chain transportation structures.
Typical applications include:
Refrigerated truck panels
Cold-chain container panels
Insulated transportation structures
Thermal insulation boards
Its closed-cell structure provides water resistance and low thermal conductivity, while its mechanical strength allows lightweight panel structures to be developed.
MPP provides cushioning, impact protection and thermal insulation while reducing packaging weight.
Typical applications include:
Protective packaging
Tool case inserts
Equipment packaging
Precision product protection
Transportation cushioning
Luggage liners
The lightweight structure can reduce transportation weight while maintaining cushioning and protection performance.
MPP provides a high strength-to-weight ratio and impact absorption capability for lightweight protection and structural applications.
Potential applications include:
Aircraft interior components
Seat cushioning
Instrument panels
Lightweight interior parts
UAV components
Protective equipment
Helmets and impact-protection structures
Application data indicates MPP can combine lightweight construction, high strength, impact absorption, temperature resistance and flame resistance for demanding lightweight applications.
The fine and uniform cellular structure, low weight and good machinability make MPP suitable for model manufacturing and selected consumer products.
Typical applications include:
Aircraft models
Marine models
Children's toys
Lightweight structural models
Hobby products
The uniform density and smooth surface also provide advantages during cutting and machining.
MPP can be installed between battery cells, modules and structural components to provide cushioning and dimensional compensation.
For prismatic battery systems, the material can help accommodate cell expansion while maintaining separation between adjacent components.
The relatively high compression stress of MPP also allows thinner cushioning layers to be considered where installation space is limited.
Recommended grades: MP20 / MP25
Battery packs require continuous mechanical support during vehicle operation.
MPP can be used as a support layer beneath battery modules or between the battery system and cooling structure.
Its compression resilience helps maintain contact between components while absorbing vibration and mechanical loading.
Recommended grades: MP10 / MP15
The application data specifically recommends MP10 and MP15 for battery pack bottom support because of their higher compression support and durability.
In battery thermal-management systems, the cooling plate needs to maintain stable contact with the thermal interface structure.
MPP can provide continuous mechanical support while accommodating vibration and dimensional variation.
Its advantages include:
Stable support
Lightweight construction
Compression resistance
Vibration absorption
Flame-retardant capability
Temperature resistance
MPP is particularly interesting for communication applications because its low dielectric and low-loss characteristics can help reduce electromagnetic interference from the structural material.
The microcellular structure also contributes to lightweight construction.
Typical applications include:
5G microwave radomes
Antenna covers
E-band communication equipment
MPP can be designed for different frequency bands and structural requirements.
MPP can be used as the lightweight insulation core in refrigerated transportation structures.
Its closed-cell structure provides:
Water resistance
Thermal insulation
Low thermal conductivity
Lightweight construction
Structural rigidity
This combination can help reduce vehicle weight while maintaining thermal insulation performance.
MPP can replace heavier traditional cushioning materials in applications where lightweight protection is important.
Its combination of impact absorption, thermal insulation, water resistance and machinability makes it suitable for customized protective packaging.
High-Density / High-Support Grade
MP-10 is the highest-density standard grade in the current MP series.
It provides high hardness and high compression resistance for applications requiring stronger mechanical support.
Density: 95 ± 15 kg/m³
Hardness: 75 ± 5 Shore C
Typical applications:
Battery pack bottom support
Cooling plate support
Structural cushioning
High-load cushioning
Industrial support components
MP-10 is particularly suitable when mechanical support is more important than minimum weight.
Medium-High Density / Support Grade
MP-15 provides a balance between weight reduction and mechanical support.
Density: 60 ± 15 kg/m³
Hardness: 65 ± 10 Shore C
Typical applications:
Battery pack support
Cooling plate support
Heavy-duty cushioning
Structural cushioning
Industrial equipment
MP-15 is suitable when engineers need to reduce weight while maintaining relatively high compression support.
Medium Density / Lightweight Cushioning Grade
MP-20 provides a lower-density structure while maintaining good compression resistance and mechanical strength.
Density: 50 ± 5 kg/m³
Hardness: 60 ± 5 Shore C
Typical applications:
Battery module side pads
Prismatic cell spacers
Cell-to-cell cushioning
Protective packaging
Lightweight structural components
MP-20 is one of the preferred grades for battery module cushioning applications.
Low-Density / Lightweight Grade
MP-25 is the lowest-density standard grade and is designed for applications where weight reduction is a primary consideration.
Density: 40 ± 5 kg/m³
Hardness: 55 ± 5 Shore C
Typical applications:
Lightweight cushioning
Battery cell spacers
Protective packaging
Cold-chain structures
Lightweight panels
Consumer products
MP-25 provides the lowest weight among the four standard grades while retaining the fundamental performance characteristics of MPP.
Property | MP-10 | MP-15 | MP-20 | MP-25 |
|---|---|---|---|---|
Density (kg/m³) | 95 ± 15 | 60 ± 15 | 50 ± 5 | 40 ± 5 |
Hardness (Shore C) | 75 ± 5 | 65 ± 10 | 60 ± 5 | 55 ± 5 |
Tensile Strength (MPa) | ≥3.0 | ≥2.0 | ≥1.8 | ≥1.5 |
The grade progression is designed around a clear trade-off:
MP-10 → Higher Support / Higher Density
MP-15 → Balanced Support & Weight
MP-20 → Lightweight + Cushioning
MP-25 → Minimum Weight + Cushioning
The technical data are based on GB/T 6343-2009 for density, GB/T 531.1 for hardness and GB/T 528-2009 for tensile strength.
MPP provides adjustable compression performance according to grade and application.
Compression Stress | MP-10 | MP-15 | MP-20 | MP-25 |
|---|---|---|---|---|
@10% Compression (MPa) | 0.26–0.80 | 0.18–0.68 | 0.12–0.50 | 0.08–0.27 |
@50% Compression (MPa) | 0.55–1.24 | 0.40–0.90 | 0.30–0.80 | 0.24–0.55 |
@70% Compression (MPa) | 0.80–1.75 | 0.55–1.60 | 0.45–1.20 | 0.35–0.80 |
Test method: ASTM D3574.
The compression curves are particularly important for battery applications because material selection should not be based only on density.
Engineers should consider:
Required Compression → Cell Expansion → Available Gap → Long-Term Load → Support Requirement
For higher-load battery support, MP-10 and MP-15 are generally more suitable.
For lighter cell spacing and cushioning applications, MP-20 and MP-25 can provide a better weight-to-performance balance.
Property | MP-10 | MP-15 | MP-20 | MP-25 |
|---|---|---|---|---|
Thermal Conductivity (W/m·K) | ≤0.05 | ≤0.05 | ≤0.05 | ≤0.05 |
Typical Thermal Conductivity (W/m·K) | ~0.042 | ~0.044 | ~0.042 | ~0.043 |
Flame Rating | UL94 HF-1 | UL94 HF-1 | UL94 HF-1 | UL94 HF-1 |
Long-Term Service Temperature | Up to 110°C | Up to 110°C | Up to 110°C | Up to 110°C |
Insulation | ≥500 MΩ | ≥500 MΩ | ≥500 MΩ | ≥500 MΩ |
Voltage Resistance | <1 mA | <1 mA | <1 mA | <1 mA |
Environmental Compliance | RoHS / REACH | RoHS / REACH | RoHS / REACH | RoHS / REACH |
The above technical data are based on the company's MPP technical presentation and specified test methods.
MPP Foam can be supplied in different densities, thicknesses and dimensions according to the customer's application.
Grade | Density | Hardness | Main Characteristics | Typical Applications |
|---|---|---|---|---|
MP-10 | 95 ± 15 kg/m³ | 75 ± 5 HC | Highest support | Battery base support, structural cushioning |
MP-15 | 60 ± 15 kg/m³ | 65 ± 10 HC | High support / lower weight | Battery support, cooling plate support |
MP-20 | 50 ± 5 kg/m³ | 60 ± 5 HC | Balanced cushioning | Cell spacers, module side pads |
MP-25 | 40 ± 5 kg/m³ | 55 ± 5 HC | Lightweight | Lightweight cushioning, packaging |
MPP can be customized according to:
Density
Thickness
Width and length
Hardness
Compression stress
Cell structure
Flame-retardant performance
Surface structure
Lamination
Adhesive backing
Die-cut geometry
Customized mechanical performance
For application-specific requirements, the compression curve can be optimized according to the customer's loading conditions and component design.
MPP rolls or sheets can be slit into customized widths for downstream processing and automated assembly.
MPP can be laminated with:
Adhesive films
Functional films
Other foam materials
Insulation materials
Protective layers
Multilayer structures can be developed to combine cushioning, insulation, bonding and surface protection.
MPP can be precision die-cut into customized components.
Typical products include:
Battery cell spacers
Module side pads
Cooling plate support pads
Protective packaging inserts
Electronic cushioning components
Communication equipment components
For prototypes and low-volume customized components, MPP can be processed according to customer drawings and dimensional requirements.
MPP grade selection should be based on the application requirement rather than density alone.
MP-10 / MP-15
Suitable for:
Battery pack bottom support
Cooling plate support
Structural cushioning
High-load applications
MP-20
Suitable for:
Battery module side pads
Cell spacers
General cushioning
Lightweight structural components
MP-25
Suitable for:
Lightweight packaging
Cell spacing
Transportation cushioning
Lightweight panels
Consumer products
The basic selection logic is:
Load Requirement → Compression Stress → Density → Thickness → Weight Target → Temperature → Flame Requirement → Processing Method
MPP is produced using supercritical physical foaming technology, creating a fine and uniform microcellular structure without conventional chemical foaming agents.
MP-10, MP-15, MP-20 and MP-25 provide different combinations of density, hardness and compression performance.
Material performance can be adjusted according to the customer's requirements for density, compression force, thickness and structural support.
Slitting, laminating and die cutting enable MPP to be supplied not only as raw foam sheets but also as customized components.
The combination of low density and high mechanical strength makes MPP particularly attractive for EV, transportation, aerospace and communication applications.
Non-crosslinked PP, low VOC characteristics and compliance with RoHS, REACH and ELV requirements support applications with stringent environmental requirements.
XYFOAMS provides MPP Foam from material development and grade selection through converting and customized component production.
Material Development → Grade Selection → Performance Testing → Slitting → Lamination → Die Cutting → Customized Components → Mass Production
Whether you need a lightweight battery support pad, a 5G radome material, a cold-chain insulation panel or a customized cushioning component, MPP can be engineered around the required combination of weight, compression, strength, thermal performance and processing requirements.
Request MPP technical data, samples or customized components for your application.
