Tear and heat resistant foams used in packaging, protective packaging bags and related methods are provided. The tear and heat resistant foam can include a nonwoven substrate, a polyethylene film, and a base layer of polyethylene foam joined together by applying at least one of heat or heat and pressure to the top nonwoven substrate, the polyethylene film and the polyethylene foam to heat the first surface of the top nonwoven substrate to a temperature that is above the melting point of polyethylene film but below the melting point of top nonwoven substrate. The temperature of the polyethylene film rises causing the polyethylene film to melt and bind the top nonwoven substrate to the polyethylene foam to form the heat and tear resistant packaging foam.