• October 10, 2023

What Are the Materials for Martial Arts Mats, and How Do They Differ?

In the manufacturing of martial arts mats, three materials are commonly used: EVA foam, XPE foam, and PU sponge. Each material has its unique characteristics, production processes, and applications in various types of mats. This blog post delves into these three materials and where they find their use.

1. EVA Foam (Ethylene-Vinyl Acetate): EVA is a polymer with excellent resistance to chemical corrosion, oil, acids, and alkalis, and outstanding shock absorption properties, effectively reducing the impact and injuries from falls. EVA foam is typically manufactured using a foaming and vulcanization blending process, a common production method that yields mats with different densities and hardness. EVA puzzle mat is widely used in mats for Taekwondo, Aikido, Karate, and even for sports like Kabaddi.

EVA floor mats are relatively lightweight, making them easy to transport and store. The material's smooth surface is easy to clean and maintain. However, during the production of EVA mat, there is a potential risk of formaldehyde generation, which might pose health risks, especially to children. Formats intended for use by young children, it is recommended to produce them using 100% new materials to reduce formaldehyde content. Generally, exposing the mats to air for 3-4 days can help fully dissipate the formaldehyde and ensure safety. Additionally, EVA foam mat may show signs of wear and tear after prolonged, high-intensity use.  

2. XPE Foam (Cross-linked Polyethylene): XPE is a type of cross-linked polyethylene foam known for its excellent resistance to water and UV radiation, as well as its high shock absorption capabilities. XPE foam is created through a cross-linking process and can be manufactured in different thicknesses and hardness levels. Unlike EVA foam, the production process of XPE foam mat does not generate formaldehyde, making it a safer option.

XPE roll-out mat is commonly used for Judo, Wrestling, and combat sports like MMA, more and more people have chosen XPE roll mats for Taekwondo training in recent years. However, XPE roll-up mats may have slightly lower durability compared to EVA floor mats. They are also relatively heavier, which might require more effort in terms of transportation and storage.  

3. PU Sponge (Polyurethane): PU SPONG is a material with high shock-absorption properties often used in Heavy-duty martial arts mats. PU sponge is widely used in MMA mats, Tatami judo mats, throwing mats, and weightlifting mats, among other high-stress sports scenarios. Its structure can maintain its shape for an extended period, making it resistant to wear and tear.

The manufacturing process of PU SPONG is relatively complex, usually requiring special techniques to achieve the high shock and durability it is known for. Consequently, PU sponge MMA mats are generally more expensive than EVA foam mats and XPE roll mats. They also have the highest weight and density among the three materials. PU sponge does not produce formaldehyde during its manufacturing process, ensuring safety. 

In conclusion, the choice of Materials for Martial Arts Mats relies on the materials and their suitability for specific applications and needs. If mats are intended for children's use, formaldehyde content should be a concern. Understanding the characteristics and pros and cons of these materials during mat purchase is essential. It is advisable to follow the manufacturer's maintenance and cleaning guidelines. Additionally, regular inspections for mat wear and timely replacements are crucial to maintaining athlete safety.