Comparison of EVA, EPP, and Supercritical Foam

Comparison of EVA, EPP, and Supercritical Foam

Introduction

If you’ve been shopping for a pickleball paddle lately, you’ve probably seen manufacturers throwing around terms like EVA, EPP, and now supercritical foam. They sound impressive—but what do they actually mean, and do they matter?

Let me start with the most technical term of the bunch.

What Is Supercritical Foaming?

Supercritical foaming is a physical foaming process that uses gases—most commonly carbon dioxide or nitrogen—under extremely high temperature and pressure. When these conditions exceed what’s known as the critical point, the gas enters a supercritical state, meaning it behaves partly like a liquid and partly like a gas.

Why does that matter? Because in this state, the gas can dissolve evenly into molten polymer material.

Here’s the simplified version of the process:

  1. A supercritical gas is injected into molten polymer, creating a uniform mixture.
  2. The pressure is rapidly released, destabilizing the material.
  3. Tiny bubbles form (called nucleation), expand, and are then “frozen” in place as the material cools.

The result is a foam with extremely small, uniform cells—typically in the range of 0.1 to 10 microns, with incredibly high pore density.

Compared to traditional foaming methods, supercritical foaming produces materials that are:

  • More consistent
  • Lighter for the same strength
  • Better performing over time

Now, if that all sounded like alphabet soup, you’re not alone. I did the research, and I’ll be honest—I had to step back and simplify what actually matters.

So, let me break this down in practical terms.

Simplifying EVA, EPP, and Supercritical Foam

EVA Foam

EVA (Ethylene-Vinyl Acetate) foam is the most familiar of the three.

It’s known for being:

  • Soft and cushioned
  • Lightweight
  • Easy to mold and manufacture

Because of this, EVA is commonly used in shoes, protective padding, toys, and lower-cost sports equipment. In pickleball paddles, EVA is often associated with comfort and feel, but it does have drawbacks. Over time, EVA can break down, compress, and lose responsiveness, especially under repeated impact.

EPP Foam

EPP (Expanded Polypropylene) foam is tougher.

Its strengths include:

  • High resilience
  • Excellent energy absorption
  • Long-term durability

EPP is widely used in automotive components and protective packaging because it rebounds quickly after impact. In sports equipment, this means better shape retention and longevity compared to EVA, though it typically feels firmer.

Supercritical Foam

Supercritical foam isn’t a material by itself—it’s the process used to create it.

Foams produced using supercritical technology are:

  • Extremely lightweight
  • More uniform internally
  • Structurally efficient

Because the cells are smaller and more evenly distributed, these foams can deliver better performance without added weight. That’s why the technology is already being used in high-end sneakers and advanced packaging—and why it’s starting to appear in pickleball paddles.

Each of these foam types has clear trade-offs. Some prioritize comfort, others durability, and others weight efficiency and consistency. None are “magic,” but the differences absolutely matter—especially when you’re evaluating paddle feel, power, control, and longevity.

Still a little fuzzy? Fair enough.

The chart below will help put all of this into perspective—specifically as it relates to pickleball paddle construction.

A Few Important Notes

  1. USAP regulations do not allow EVA foam to be used as the primary core material in a pickleball paddle. The reason cited is that EVA can produce a “trampoline effect,” which may result in excessive power.
  2. Most foam-based paddles currently on the market use an EPP core with EVA foam along the perimeter or sidewalls. This construction is approved by USAP and is commonly used to improve feel and edge stability without violating core material rules.
  3. At the time of writing, HUDEF appears to be the only manufacturer producing paddles using supercritical foam technology. One key advantage is that the resilience of supercritical foam is considered extremely high, which is promising for long-term durability and resistance to performance breakdown over time.

Frequently Asked Questions (FAQ)

What foam is used in pickleball paddle cores?
Most pickleball paddles use a polypropylene-based core, often with variations such as EPP foam. EVA foam is not allowed as a primary core material under USAP rules.

Why is EVA foam not allowed as a pickleball paddle core?
USAP restricts EVA foam in paddle cores because it can create a “trampoline effect,” which may generate excessive power and reduce control.

What is the difference between EVA, EPP, and supercritical foam?
EVA foam is soft and comfortable but less durable. EPP foam is more resilient and better suited for repeated impact. Supercritical foam refers to a manufacturing process that creates extremely small, uniform cells, resulting in lightweight materials with high durability and consistency.

Are supercritical foam pickleball paddles USAP approved?
USAP approval depends on the paddle’s overall construction, not just the foam technology. As long as the paddle meets USAP specifications, the use of supercritical foam can be approved.

Do foam-based pickleball paddles wear out faster?
Some foam paddles—especially those relying heavily on EVA—may lose performance over time. Foams with higher resilience, such as EPP or supercritical foams, are expected to maintain their properties longer.

Which foam is best for pickleball paddles?
There is no single “best” foam. EVA prioritizes feel, EPP balances durability and performance, and supercritical foam aims to maximize consistency, weight efficiency, and longevity.