Ward & Kennedy supplies businesses nationwide with traditionally die-cut and high-precision digitally cut EVA. From shoe insoles to protective packaging and everything in between, you can trust Ward & Kennedy’s nearly 100-year history for fast turnaround times and dedicated service and support.
EVA is a closed-cell foam material known for its cushioning, shock absorption, and flexibility, while remaining lightweight and water-resistant. It's widely used across footwear, sports, packaging, and craft industries, particularly in applications where comfort and impact protection are priorities.
Common products made from EVA include:
EVA's density, thickness, and layering directly affect how it performs during cutting, from blade pressure to dimensional accuracy.
| Property | Description |
|---|---|
| Density | Softer EVA cuts easily but can compress under the blade, while firmer EVA needs more cutting force |
| Thickness | Thicker foam requires more pressure and can affect precision on detailed shapes |
| Closed-cell structure | Compresses slightly during cutting, which can affect final dimensions if not accounted for |
| Layering and lamination | Multi-layer or multi-color EVA sheets, common in orthotics and props, must cut evenly through all layers |
| Heat sensitivity | Can char or melt under excessive heat, which affects settings for laser-based cutting |
| Compression memory | Determines how well cut edges hold their shape after the blade passes through |
slices completely through the material, and both digital cutters and traditional dies can perform it depending on thickness and volume.
Perforation creates a line of small cuts for easy hand separation, achievable by both die cutting and digital cutting.
Digital cutting works well for prototyping EVA products and producing custom or one-off items, such as cosplay props, packaging inserts, or new footwear designs still in development. Laser and CNC knife cutting allow for quick pattern adjustments without any tooling cost.
For production runs, die cutting is the standard in industries like footwear manufacturing, where steel rule dies stamp out midsoles and insoles in large volumes. The upfront tooling cost is offset by faster cutting speeds and lower per-unit costs once a design is finalized and moving into full production.
At our facility in Milwaukee, WI, our team of designers and fabricators can help bring your vision to life. Whether you have existing design files or assistance with their creation, we’re here every step of the way.
Along with fabrics, we die cut materials like:
Ward & Kennedy has been designing, fabricating, and supplying industries all over the world since we were founded in 1928. Whether you’re in our Wisconsin backyard or located across the world in Asia, we can supply your die cut materials.
Along with fabricating parts for businesses across America, we supply them with the necessary tools, supplies, and gear to keep them running at full capacity. We stock abrasives, adhesives, PPE, and more from major brands like 3M, Dynablade, Superior Glove, Wendt and Mirka.
