This article is concerned with the general theory of expansion, manufacturing processes, properties, and applications of foamed (cellular) plastics. The high strength‐to‐weight ratio, excellent insulating properties, and cushioning properties of cellular plastics have contributed to the development and growth of the broad range of cellular plastics in use. The total usage of foamed plastics in the United States has risen from 1.4 million metric tons in 1982 to 2.2 million metric tons in 1992 and has been projected to rise to about 3.1 million metric tons in 2002. The manufacturing processes for cellular polymers are described in terms of three classified methods on the basis of cell growth and stabilization processes. The properties of cellular plastics, including mechanical, thermal, electrical, and environmental aging properties, are summarized. A general discussion is given on the properties of cellular plastic necessary in many applications such as the comfort cushioning, thermal insulation, packaging, structural components, buoyancy, electrical insulation, and space‐filling markets. A brief discussion is also given on the process economics, raw materials, and energy considerations for the commercial products of primary importance.
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