All mats are not the same. XPE polyethylene foam mats have unique qualities that set them apart from other major foam mats like EVA, EPE and rubber. Durable, resilient, and shock-absorbing, XPE mats are quickly becoming the gold standard in athletic training. Through the use of a technologically advanced manufacturing process, XPE mats are soft but also resistant to the wear and tear of life. Boasting a unique ability to prevent moisture absorption and being anti microbial, these mats will quickly become the favourite, go-to mat in your gym. XPE mats are readily available in stock at British Martial Arts Mats, so you can purchase them whenever you need them.
Key Takeaways
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XPE mats provide superior shock absorption and durability, making them ideal for martial arts training, especially in high impact disciplines like judo, BJJ, and taekwondo.
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Thanks to their closed cell structure, XPE mats are water-resistant, anti-microbial, and odour free, ensuring a clean, safe, and hygienic training environment.
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Compared to EVA and EPE, XPE mats maintain shape better under pressure, offer enhanced grip, and are more resistant to wear and tear over time.
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At British Martial Arts Mats, we sell premium quality XPE mats in various sizes, perfect for martial artists of all levels.
What Are XPE Foam Mats?
In order to truly appreciate the quality and craftsmanship that goes into XPE foam, you need to delve into the unique manufacturing process involved. XPE is a cross-linked polyethylene foam which is ideal for projects that require thick foam. Through a chemically unique process, a mutual cross-linking occurs between polyethylene particles, creating a netlike structure. As a result, once cured, the walls of the material form an embedded cellular structure. Strong, dense, and durable, XPE is a collection of fine-celled particles which have superior physical and chemical properties.
Possessing an unique thermal and insulating properties, XPE foam is used in the automotive industry in processes where friction creates high heat. Some of the best uses of XPE foam are for expansion joints and industrial gaskets.
Another added benefit of polyethylene foam is that it has strong rigidity. When an athlete steps on the mat, the mat will spring back to its original shape almost instantly. This allows for great shock absorption for athletes who land on the mat.
Because of the manufacturing process, XPE foam has a soft outer shell which is resistant to moisture. XPE mats have low moisture permeability. This means that XPE mats possess antimicrobial qualities which make them extremely useful to use in athletic training, where sweat may come into contact with the mat.
Features and Benefits of XPE Mats
One of the standout features of XPE mats is their water-resistant nature. Spills and stains are no match for these mats; simply wipe them clean with a wet cloth, and they’re as good as new.
Safety is paramount when it comes to products for martial arts, and XPE mats excel in this area. They are non-toxic and BPA-free, ensuring that everyone playing or training on the surface is free from harmful chemicals. This peace of mind is invaluable for parents who prioritise their children’s health and safety.
In terms of value, XPE mats offer a durable and long-lasting play surface that stands up to regular use. They are resistant to wear and tear, making them a practical investment for everyone. The combination of these features makes XPE mats a good value for their price, providing a high-quality product that doesn’t break the bank.
Maintenance is a breeze with XPE mats. Their water-resistant properties mean that cleaning is as simple as wiping them down with a damp cloth. This ease of maintenance is a significant advantage.
Choosing the Right XPE Mat for Martial Arts Training
When it comes to martial arts training, choosing the right XPE mat is crucial for safety, performance, and comfort. Whether you're practising striking arts like karate or taekwondo or grappling disciplines like judo and Brazilian jiu-jitsu, the right mat provides the necessary support to train effectively and reduce the risk of injury.
One of the first things to consider is impact absorption. High-density XPE mats are known for their excellent shock absorption, which is essential for protecting joints during high-impact movements, takedowns, or throws. A mat that cushions fall without being too soft helps maintain stability and reduces strain during long training sessions.
Surface texture and grip also play a key role. Mats with a non-slip surface help prevent accidental slips during sparring, drills, or kata. This is especially important in high-speed training or when executing intricate footwork, where stability and balance are vital.
Mat size and layout flexibility should match the scale of your training space. For home gyms or dojos, larger mats or interlocking tiles offer customisation to cover wider areas. Compact spaces might benefit from foldable or rollable XPE mats that can be easily stored after each session.
While these mats are ideal for martial artists of all levels, they also work well for children starting out in martial arts. The same durability and safety features make XPE mats suitable for family training environments, ensuring everyone can train confidently and comfortably.
In short, investing in the right XPE mat means better safety, improved performance, and a more enjoyable martial arts journey, whether you're a beginner or a seasoned pro.
What Are EVA Mats?
EVA stands for ethylene-vinyl acetate, and is an extremely versatile and durable substance. Also a closed-cell foam, EVA is water resistant. EVA is a flexible plastic, which is used in anything from toys to puzzle piece flooring.
EVA plastic is converted to foam through either injection or compression moulding processes. In either process, bubbles and high heat are introduced into the mix, and this creates an unique closed-cell structure, which is actually quite similar to XPE. This unique process creates an easily mouldable material which is resistant to UVA radiation. A highly durable material with rubber-like flexibility, EVA is a step up from any open-celled foam because it is firmer and allows for greater shock absorption.
EVA can also be easily cleaned and disinfected, and this allows it to be used in gyms and dance studios. Its ubiquity is because of its effectiveness and durability, and is commonly referred to as “foam rubber” even though it doesn't contain any rubber.
EPE Mats
Another major type of athletic mats are EPE mats. EPE foam is created when low-density polyethylene is injected with butane gas, creating a non-cross linked, closed-cell structure comprising many bubbles. EPE is the cheapest foam material and is used for packing and shipping purposes, and also flooring underlayment.
One major advantage of EPE is that it is extremely lightweight, making it easier to transport. Since its first manufacturing in the 1970s, EPE foam has quickly replaced polystyrene in impact absorption applications.
Lacking the same elasticity of EVA and the shock absorption qualities of XPE, EPE is the least durable material available on the market for athletic mats. To put things into perspective, EVA is almost five times more durable than EPE.
Rubber Mats
On the other end of the spectrum, rubber mats are the most dense athletic mats that can be purchased. Rubber mats are made from recycled tyres which have been chopped up, melted, and spread out to form a mat. Although incredible in impact resistance, rubber mats are not the softest mats to land on, and lose out to XPE, EVA, and EPE in shock absorption qualities.
What's the difference between XPE and EVA?
The major difference between XPE and EVA mats is the manufacturing process used to create the mats. EVA is created through the use of an industrial chemical called formamide, which gives an acrid odour to the product. Although in liquid form, formamide is toxic, during the manufacturing process, formamide evaporates, and the small amount that is left slowly evaporates over time. Many government agencies have done studies on formamide and found it to be harmless at the levels that are found in EVA mats. The government of Canada conducted a scientific screening to determine if there were any ill effects and found “that formamide is not harmful to human health at current levels of exposure” [1]. Although EVA mats are not hazardous to your health, they're produced in a much less environmentally friendly way than XPE.
As a result of the manufacturing process, EVA mats off-gas formamide which has a unique ammonia-like smell [2]. This smell usually lingers in new EVA mats for several weeks. What sets XPE mats apart from EVA is that XPE mats are odourless, which makes a substantial difference when you regularly use the mats.
EVA foam mats have some benefits that outmatch XPE mats. For example, EVA foam has a fine outer skin which is much softer than XPE. EVA mats are also more popular than XPE because it's much more economical to make them. The primary reason for EVA's popularity is that it can reach 50mm in thickness without lamination, making EVA ideal in die cutting manufacturing.
Alternatively, XPE mats are produced through a continuous foaming process, which allows for the length to be much longer than EVA. This means that longer sections of XPE can be created than EVA.
XPE mats result from an innovative new manufacturing process which creates thick, durable, antibacterial athletic mats. Unlike EVA mats, which have a unique smell, XPE mats are free from odours. However, EVA mats can be perfectly useful when used in 20mm or 40mm thick puzzle tiles, providing an entire space with coverage. However, the most important difference is that XPE mats are formed in a continuous foam roll of tight, cross-linked closed cells. This translates directly to you in a quality product over several metres of mat.
Ultimately, the type of mat that fits your space depends entirely on what you'll do on it, but XPE offers the best quality for the price.
References
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canada.ca/en/health-canada/services/chemical-substances/challenge/batch-5/formamide.html
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https://en.wikipedia.org/wiki/Formamide. Formamide is derived from ammonia and formic acid and has an ammonia-like smell. From all the research, it seems that ammonia is on the peripherals of the manufacturing process of EVA mats but lends its unique smell to the product.
Author: Dave Van Kooten
