Global Extruded Polypropylene (XPP) Foam Market Size Study & Forecast, by Type, End-use, and Regional Forecasts 2025–2035

The Global Extruded Polypropylene (XPP) Foam Market is valued at approximately USD 1.38 billion in 2024 and is anticipated to expand at a compound annual growth rate (CAGR) of 6.50% over the forecast period from 2025 to 2035. Extruded polypropylene foam, owing to its remarkable resilience, high heat resistance, and recyclability, has emerged as a preferred solution across diverse industries including automotive, packaging, construction, and furniture. As consumer expectations veer toward eco-conscious and lightweight materials, manufacturers are leaning on XPP foam to strike the delicate balance between functionality and sustainability. Notably, the automotive industry is leveraging XPP’s lightweight and energy-absorbing characteristics to enhance fuel efficiency and passenger safety, in line with regulatory frameworks and emission norms.

Moreover, the material's suitability for thermoforming and structural durability has led to increased adoption in reusable packaging applications and protective cushioning solutions. Particularly within packaging and logistics, where e-commerce boom and global trade expansion continue to challenge supply chains, XPP foam offers a reliable solution for impact protection and insulation. The growing preference for flexible, lightweight construction solutions is also spurring demand across the building & construction sector. The rising adoption of advanced foaming technologies, coupled with the increasing integration of closed-loop recycling systems, is amplifying the commercial potential of XPP foam as a sustainable alternative to conventional polymeric materials.

From a regional perspective, North America remains a dominant player in the global XPP foam market landscape, driven by mature automotive manufacturing hubs, cutting-edge R&D infrastructure, and an emphasis on lightweight material adoption. Meanwhile, the Asia Pacific region is witnessing the fastest growth, fueled by rapid industrialization, urban development, and government support for sustainable manufacturing practices in countries like China, India, and Japan. The region’s thriving automotive sector, coupled with growing investment in smart packaging and green building materials, is propelling demand. Europe, on the other hand, continues to lead in innovation with stringent regulations promoting circular economy practices and environmental performance, pushing forward the use of recyclable and high-performance foam products.

Major market players included in this report are:
• BASF SE
• Borealis AG
• DS Smith Plc
• JSP Corporation
• Pregis LLC
• Furukawa Electric Co., Ltd.
• Kaneka Corporation
• Toray Industries Inc.
• Sekisui Voltek, LLC
• Zotefoams Plc
• Hanwha Solutions
• Mitsui Chemicals Inc.
• Sonoco Products Company
• Recticel N.V.
• The Woodbridge Group

Global Extruded Polypropylene (XPP) Foam Market Report Scope:
• Historical Data – 2023, 2024
• Base Year for Estimation – 2024
• Forecast period – 2025–2035
• Report Coverage – Revenue forecast, Company Ranking, Competitive Landscape, Growth factors, and Trends
• Regional Scope – North America; Europe; Asia Pacific; Latin America; Middle East & Africa
• Customization Scope – Free report customization (equivalent up to 8 analysts’ working hours) with purchase. Addition or alteration to country, regional & segment scope*

The objective of the study is to define market sizes of different segments & countries in recent years and to forecast the values for the coming years. The report is designed to incorporate both qualitative and quantitative aspects of the industry within the countries involved in the study. The report also provides detailed information about crucial aspects, such as driving factors and challenges, which will define the future growth of the market. Additionally, it incorporates potential opportunities in micro-markets for stakeholders to invest, along with a detailed analysis of the competitive landscape and product offerings of key players.

The detailed segments and sub-segments of the market are explained below:

By Type:
• Rigid PVC
• Flexible PVC

By End-use:
• Automotive
• Packaging
• Building & Construction
• Furniture & Bedding

By Region:

North America
• U.S.
• Canada

Europe
• UK
• Germany
• France
• Spain
• Italy
• Rest of Europe

Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• Rest of Asia Pacific

Latin America
• Brazil
• Mexico

Middle East & Africa
• UAE
• Saudi Arabia
• South Africa
• Rest of Middle East & Africa

Key Takeaways:
• Market Estimates & Forecast for 10 years from 2025 to 2035.
• Annualized revenues and regional level analysis for each market segment.
• Detailed analysis of geographical landscape with Country level analysis of major regions.
• Competitive landscape with information on major players in the market.
• Analysis of key business strategies and recommendations on future market approach.
• Analysis of competitive structure of the market.
• Demand side and supply side analysis of the market.

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