XLPU Rigid polyurethane (PU) foams

Rigid polyurethane (PU) foam blocks and sheets

Excel Packaging is excited to introduce XLPU Foam, our new range of Rigid polyurethane (PU) foam blocks and sheets. Just like our Polystyrene blocks and sheets, this product has been designed with versatility in mind, XLPU Foam is the perfect choice for film & theatre set construction, prop making, model making, prototyping and composite structures. Lightweight yet strong, XLPU Foam is easy to cut, carve, sculpt or shape and paint. With a wide range of densities and colours available, you’ll find a grade that suits everything from delicate sculpted models to large set pieces or demanding structural cores.

All sheets are available in standard sheet sizes with thicknesses made to order from 5mm. A Fire-retardant grade (XLPU38FRA) is also available upon request. We also offer a fast 5-7-day lead-time to keep your projects on schedule.

Sizes & Specifications

Product Ref	Colour	Density	Standard Sheet Size	Max Thickness
XLPU32	Beige	32 kg/m³	2440 × 1220 mm	800 mm
XLPU38FRA	Beige	38 kg/m³	2440 × 1220 mm	800 mm
XLPU48	Grey	48 kg/m³	2440 × 1220 mm	650 mm
XLPU64	Grey	64 kg/m³	2440 × 1220 mm	350 mm
XLPU80	Dark Grey	80 kg/m³	2440 × 1220 mm	325 mm
XLPU96	Green	96 kg/m³	2440 × 1220 mm	300 mm
XLTPU128	Beige/Yellow	128 kg/m³	2000 × 1000 mm	300 mm
XLTPU160	Beige/Yellow	160 kg/m³	2000 × 1000 mm	300 mm
XLTPU192	Beige/Yellow	192 kg/m³	2440 × 610 mm	260 mm
XLTPU256	Beige/Yellow	256 kg/m³	2000 × 1000 mm	220 mm
XLTPU320	Beige/Yellow	320 kg/m³	2440 × 610 mm	155 mm

Key Benefits

Wide range of densities available (32–320 kg/m³) for different applications.
Easy to shape, carve, sculpt and paint which is ideal for creative builds.
Suitable for film set construction, props, model making and prototype construction.
Strong and lightweight and excellent as a composite core material.
A fast 5–7-day delivery across the full range of products.

Applications

Film & Theatre: Sculpted sets, props and stage pieces.
Model Making & Prototyping: Detailed, precise forms with smooth finishes.
Creative Industries: Art installations, exhibitions and large-scale displays.
Composites & Engineering: Lightweight, structural foam cores for laminating.

Excel image gallery

XLPU Foam range (32 kg/m³ - 96 kg/m³ grades)

XLPU32 partial-depth knifing

XPLU Foam strips

XLPU96 raw material

XLPU96 sliced into squares

Various grades carved into Lego^® bricks

Testimonials

Excel Packaging are a great company. We have dealt with them for decades because they have consistently given us fantastic customer service. They are up to date on the latest regulations and raw materials. They have a huge range of skills and knowledge in a wide range of special packaging materials and are worth a call. Most recently, they have helped with sustainable foam products.

Luke Jamieson

Aylesbury Box Co
Since being introduced to Excel Packaging we have found them to be an excellent supplier, communication is excellent and we really appreciate the personal service. All too often now e-mail seems the first point of contact but you tend to lose content in messages. Mark is always keen to visit and fully understands and provides solutions to our requests, backed up with samples and all in a timely manner. Excel are a gem of a company that are too often hard to find these days. Keep up the good work.

Justin Burrell

Barton Jones Packaging Ltd