- Manufacturing: XPS is extruded; EPS is expanded from molded beads.
- Structure: XPS has a homogeneous closed-cell structure; EPS has a more porous, bead-based structure.
- Compressive Strength: XPS generally has higher compressive strength than EPS of equal density.
- Moisture Resistance: XPS has much lower water absorption and superior vapor diffusion resistance.
- R-Value: XPS typically has a higher R-value per inch (R-5) than standard EPS (R-3.6 to R-4.2).
- Cost: XPS is generally more expensive than EPS.
- Sustainability: EPS often has a lower Global Warming Potential (GWP) from blowing agents.

