How is bubble wrap made?

Bubble wrap is an amazing 1957 invention for pretty well foolproof packing of fragile items such as china. Unfortunately, this excellent wrapping material depends on plastic. Bubble wrap is formed from polyethylene resin. This is melted to make plastic sheets. One sheet is placed over a template with holes.

Suction pulls plastic into each hole and this makes the bubble shape. A second sheet of plastic is laid over the first, then all is heated to seal the air inside. It is this system of trapped air inside soft material that cushions the wrapped items from movement in transit.

The first bubble wrap manufacturing machine was made in 1957. The process to make bubble wrap starts with plastic resin pellets made of different materials. For example, nylon resin pellets are used to add strength to the bubble wrap. The pellets are vacuumed into an extruder that melts the pellets at high temperature to make a film.

The film flows over cylinders to create the necessary thickness needed. The film then goes over another cylinder with holes that are vacuumed to form the shape and size of bubble needed. The sheets of bubble wrap are then cut to size and perforated like a paper towel.