Polyethylene foam comes in either molded or fabricated forms. The fabricated product is extruded, die cut and heat sealed to produce the desired result. It can also be saw cut and laminated to corrugated. Both molded and fabricated polyethylene can be used to provide similar protection for an item. The volume required will most likely determine whether the polyethylene is molded or fabricated. Fabricated polyethylene typically requires a cutting die to produce the fabricated part. These cutting dies require a one- time, up-front charge. Typically, these charges will range from $1000 to $2,000 each piece. The typical mold for the molded polyethylene item could cost $15,000 to $25,000. These molds take approximately 4-6 weeks to produce.
