Cedar Mill Firearms Hard Pistol Case With Form Inserts

Comparison Between PU, EPE, and EVA Foam for Gun Cases

The type of foam used in the gun case can make a big difference in how well it performs. There are three main types of foam that are commonly used in gun cases: PU (polyurethane), EPE (expanded polyethylene), and EVA (ethylene vinyl acetate).


This post highlights their properties, advantages, and disadvantages, and helps you choose the best foam for your gun case.

PU (Polyurethane) Foam

PU Form Inserts

PU foam is a soft, open-cell foam that offers good cushioning and shock absorption. It is easy to customize and fabricate so that it perfectly fits a custom firearm case. PU foam is also cheap to manufacture and lightweight, making it a popular choice for the packaging industry.

However, PU foam also has some drawbacks. It is fragile and flimsy, and it does not have a long lifespan. It tends to come apart at the edges, deform underweight, and eventually become unusable.

PU foam has an open cell matrix that contains air spaces, which makes it deformable and gives it a spongy look. Due to its low density, PU foam absorbs water like a sponge, which can cause rusting and corrosion of the firearm if placed wet in the case.

PU foam is suitable for disposable or short-term use, as it is cheap and easy to replace. It can also be used in pick and pluck variants, which allow the user to customize the shape of the foam by removing small pieces of foam.

EPE (Expanded Polyethylene) Foam

EPE foam is a hard, closed-cell foam that offers excellent strength, resilience, and durability. It is resistant to deformation, compression, and tearing, and can withstand high temperatures and pressures. EPE foam also has a closed cell matrix (without air spaces), which makes it water-repellent and moisture-resistant. EPE foam does not absorb water, hence preventing rust and corrosion of the firearm.

A Discreet Concealment Guitar-Shaped Gun Case showing EPE Cutout Form Fitted With A Rifle and Accessories

EPE foam is ideal for long-term storage. It is also suitable for humid environments. The foam can be custom-shaped and fabricated to fit the firearm case and be laminated with other materials to enhance its appearance and performance.

EVA (Ethylene Vinyl Acetate) Foam

An EVA form cutout for a pistol case

EVA foam, like EPE, is also a hard, closed-cell foam. It however has varied texture and appearance compared to EPE foam. EVA foam has a smooth and rubbery finish, and it is very rigid and firm. EVA foam has a clean and sleek look and is often used for display cases and showcases.

EVA Foam Advantages 

  • Water-repellency
  • Moisture-resistance
  • Durability
  • Does not absorb water
  • Resistant to deformation, compression, and tearing
  • Can withstand high temperatures and pressures


  • Expensive than PU foam
  • Heavier and bulkier
  • Hard to cut and shape, and it requires special tools and equipment

Here is a table that summarizes the comparison between PU, EPE, and EVA foam for gun cases:

Foam Type Properties Advantages Disadvantages
PU (Polyurethane) Soft, open-cell, cushioning, shock-absorbing Cheap, lightweight, easy to shape, pick and pluck variants Fragile, flimsy, short lifespan, water-absorbing, poor anti-abrasive, deforms under weight
EPE (Expanded Polyethylene) Hard, closed-cell, strong, resilient, durable Water-repellent, moisture-resistant, prevents rusting, resistant to deformation, compression, and tearing, can be laminated More expensive, heavier, bulkier, harder to cut and shape, rough and coarse texture
EVA (Ethylene Vinyl Acetate) Hard, closed-cell, smooth, rubbery, rigid, firm Water-repellent, moisture-resistant, prevents rusting, resistant to deformation, compression, and tearing, clean and sleek look, good for display More expensive, heavier, bulkier, harder to cut and shape, smooth and slippery surface, less secure and stable

High-quality EPE Form inserts


The type of foam used in a gun case can affect its performance, durability, and appearance. As you can see, there is no definitive answer to which type of foam is best for your gun case. It depends on various factors such as your gun’s size, shape, weight, value, and usage frequency; as well as your personal preferences regarding comfort, convenience, aesthetics, and price.

To help you make an informed decision, here are some general guidelines:

  • If you want a soft and flexible foam that can easily conform to your gun’s shape, choose PU foam.
  • If you want a lightweight and resilient foam that can withstand repeated use without losing its form, choose EPE foam.
  • If you want a tough and elastic foam that can provide optimal protection for your gun from impact and vibration, choose EVA foam.


Disclaimer: This post contains affiliate links. If you make a purchase, we may receive a commission. This won’t affect your purchase price.

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