Silicone Foam
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What is Silicone Foam?
Silicone foam – also known as foamed silicone or silicone sponge – is a durable, flexible foam with a long service life. Available as open-cell (cushioning/comfort) and closed-cell (sealing/gasketing).
Also available as 2-component RTV silicone foam for casting and encapsulating parts. Optionally fire-resistant/flame-retardant (e.g. UL 94 V-0) for electronics and battery applications.
Why choose it: Silicone foam combines high temperature resistance, UV/weather resistance and lasting elasticity. Ideal for protecting electronics, battery packaging (EV/energy storage) and cushion fillings.
Who it is for: Designers and engineers in electronics, battery/EV, mechanical engineering and HVAC; product developers in wearables/clothing and manufacturers of cushions or comfort parts.
Key benefits
- ✓Durable and weather-resistant does not harden or crumble
- ✓Thermal range usable from low to high temperatures
- ✓Open-cell vs closed-cell choice of cushioning or sealing
- ✓Fire-resistant options including UL 94 V-0 silicone foam
- ✓RTV 2-component controlled expansion and curing
Application methods
- →Closed mould for a stronger/more compact foam effect
- →Venting/overflow large escape opening when pressure builds up
- →Layer by layer small batches to prevent over-expansion
Processing & curing
Curing mechanism
2-component RTV silicone foam reacts at room temperature. Gas is formed while mixing components A and B.
Ideal conditions: Work at moderate temperatures; too warm = gelling too fast, too cold = slow curing.
- Check mixing ratio & mix homogeneity
- Predictable expansion through the right temperature
Modifiers
Silicone oil lowers viscosity and reduces foaming intensity.
Fillers/pigment for colour and mechanical tuning (only if compatible).
- Gas is trapped in the foam structure
- Consistent cell structure through correct processing
Specifications and selection
Density & compression set
Choose density and compression set based on the application: lower density for comfort/cushioning, higher density for gaskets/sealing.
Temperature range
Silicone foam remains functional over a wide range (e.g. from −60°C to +200°C, depending on the product line).
Open-cell vs closed-cell
Open-cell absorbs and cushions. Closed-cell seals and springs back.
Compatibility & applications
Electronics & potting
Insulation, cushioning and flame retardancy around sensitive components
Batteries/EV
Battery packaging, spacing and thermal/insulating layers
Cushions/comfort
Lasting soft-touch cushioning without PU ageing
Sealing
Closed-cell silicone foam as a gasket (check compression set)
Tips for the best result
Mould work & pressure control
- → Use a closed mould for a more intensive foam effect
- → Vent around sensitive parts
- → Regulate pressure with generous overflow/venting
Viscosity & expansion
- → Lower viscosity with silicone oil
- → Work in small quantities
- → Evaluate expansion per batch
Environmental control
- → Control the ambient temperature
- → Consistent cell structure through the right conditions
- → Check the data sheet for compatibility
Frequently asked questions (FAQ)
What is the difference between silicone foam and silicone sponge?
Both terms refer to silicone foam. "Sponge" is often used for sheet material/rolls; "foam" for cast or 2K applications.
When should I choose open-cell or closed-cell silicone foam?
Choose open-cell for cushioning/comfort; closed-cell for sealing and gaskets (battery/electronics/environment).
Is fire-resistant (UL 94 V-0) silicone foam available?
Yes, select flame-retardant grades (e.g. UL 94 V-0). Check certification and application limits in the data sheet.
Can I cast 2-component RTV silicone foam around electronics?
Yes, provided it is compatible with the components and curing; vent or use an overflow to limit pressure. Always test on a small scale first.
Get started
Choose open-cell or closed-cell silicone foam for your application. For UL 94 V-0 electronics/batteries, select fire-resistant lines. Want to cast 2-component RTV silicone foam? Contact us for mixing and expansion advice.