Custom Foam Inserts
Our bespoke cushioning solutions keep each part in place, so even your most delicate items stay safe and secure during hard drops.
| Feature | Specification / Detail |
|---|---|
| Material Options | Closed-cell Polyethylene (PE), Open-cell Polyurethane (PU), EVA |
| Standard Densities | 1.7 lb/ft³ to 6.0 lb/ft³ |
| Cutting Method | CNC Routing, Waterjet Cutting, or Die-Cutting |
| Color Availability | Charcoal, Black, Blue, Red, White and Custom Laminates |
| Compliance | REACH & RoHS Compliant; Anti-static options available |
| Temperature Range | -40°F to 160°F (Depending on material) |
Precision-Engineered Protection That Keeps Everything Secure
When you open a case and find your gear just where you left it, you get more than organization — you get peace of mind. We’ve tested these inserts in all kinds of cases, from tough military crates to stylish presentation boxes, and found that precise milling makes all the difference.
Generic "pick-and-pluck" foam often breaks down and leaves a mess, but our custom-cut inserts fit your device exactly. When carrying heavy lenses or sensitive electronics, the high-density foam keeps its shape and grip, so your gear stays secure and doesn’t rattle.
Foam Types Designed for Every Use
We know that one type of protection doesn’t fit everyone. That’s why we use different foam types to get just the right mix of softness and strength for your needs:
- Polyethylene (PE) is a closed-cell foam that is tough and stands up well to chemicals and moisture. It’s often used for heavy tools and industrial equipment because it’s so reliable.
- Polyurethane (PU) is an open-cell foam that’s soft and flexible. It works well for lightweight items like jewelry or delicate electronics that need gentle, springy cushioning.
- EVA Foam (Ethylene-Vinyl Acetate) is a high-quality, dense closed-cell foam with a smooth finish and excellent crack resistance. We consider it the best choice for luxury displays and medical instruments because it feels soft but is very durable.
- Anti-Static Foam is specially made to get rid of static electricity, which helps protect delicate circuit boards and microchips from hidden damage.
Make Your Presentation and Brand Stand Out
The way your customer opens a case matters. A neat, organized case shows you care about your work. Many clients add die-cut inserts for extra layers or include brand story cards in a special foam slot to connect with buyers right away.
Why Choose Custom-Milled Foam Instead of Standard Padding?
Standard egg-crate foam or loose-fill peanuts can cause "point loading," which means the weight of your item presses on a small spot and may cause damage. Our custom-milled cavities spread the weight evenly across your item.
In our stress tests, items packed in custom-fit PE foam survived drops from heights 40% higher than those wrapped in bubble wrap or loose partitions. If you ship delicate instruments, you can also add user manuals or warranty cards in a precision-cut lid pocket to keep your documents organized with your equipment.
Frequently Asked Questions About Custom Foam Inserts
Here are answers to the questions we hear most often. We hope this helps you figure out exactly what you need for your project.
Read our Custom Packaging Support & Ordering FAQs →What is the difference between open-cell and closed-cell foam?
Open-cell foam, like Polyurethane, is soft and breathable, similar to a sponge. It works best for lightweight or delicate items. Closed-cell foam, such as Polyethylene or EVA, is dense and water-resistant, so it’s great for heavy items, tools, or places where the foam might get wet or greasy.
Can I get multiple colors in a single foam insert?
Yes, we offer multi-layered foam, also called "shadowing." This usually means a bright base layer, like red, with a dark top layer, like black. If a tool or part is missing, it’s easy to spot right away. This feature is especially important in aviation and medical fields.
How do I provide the dimensions for my custom cutouts?
You can send us a physical sample, a CAD file (like DXF or DWG), or a clear photo with a size reference. For complex shapes, a digital file helps us make sure your items fit tightly and don’t move during shipping.
Is the foam resistant to oils and chemicals?
Our closed-cell Polyethylene and EVA foams resist most industrial chemicals, oils, and fuels. That’s why they’re a top choice for mechanic tool sets and industrial kits where spills can happen.
Can you add branding or logos to the foam itself?
Yes, we can laser engrave logos, part numbers, or instructions right onto the foam. This means you don’t need extra labels that might peel off, and it gives EVA foam inserts a high-end look.
What is the minimum order quantity for custom projects?
We usually make large orders for manufacturers, but we’re happy to help with smaller projects too. Whether you need just one insert for a camera case or 5,000 for a product launch, our CNC process lets us scale up or down without high setup costs.
