Important Information Regarding Foam Inserts

Foam inserts, as the name suggests, are used for packaging and filling out packages. There is a wide range of packaging foam available for this purpose. Today, one can purchase custom foam inserts in following formats:

  1. Polyethylene
  2. Closed cell polyethylene
  3. Polyether
  4. Polyurethane
  5. Neoprene
  6. Stratocell

Foam inserts can also be made available in laminated finishes using suede, leather and other combinations along with a self adhesive backing layer.

How to choose the right foam inserts for your needs?

Choosing the right quality and material of foam is essential to protect your stored items. The PE or polyethylene foam is a lot denser than other varieties and offers a tight and secure fit. On the other hand, the Ester or polyurethane foam is spongier but gives excellent shock absorption.  To summarize, you can:

1. Choose the PE (polyethylene) foam when you want to be able to cut it with ease to fit the objects. PE foam is typically used for storing medium to heavy objects or objects that can manage a small amount of shock such as electric drills etc. These foams are also available in solid and anti-static options.

2. Choose the Polyurethane or Ester foams for complex and irregularly shaped objects like the SLR cameras etc. This soft but durable foam can protect delicate objects from modest impacts.

Options in Case foams

Case foam can be configured in various ways. Solid foam pads can be used for lining up the bottom to form an inch or two of cushioning. This cushioning helps prevent the objects from coming into contact with the case. In smaller cases, a single solid pad can be used, whereas for larger cases, you can use multiple solid pads to accommodate multiple objects.

Convoluted foam inserts, also known as egg carton inserts, are perfect for thinner cases used for transporting objects that cannot withstand any movement during transport.

A better alternative available today is the bespoke or customizable foam inserts. There are several ‘pick and pluck’ cases that use a solid base pad on the bottom and can also be filled with polyurethane foam cut in removable cubes. To accommodate your items, you simply need to remove the individual cubes to make space.

Methods of cutting foam

There are many state-of-the-art foam cutting techniques that give you computer controlled-precision cuts in foams. These include:

1. Die cut- Steel cut dies are used for precisely cutting the foam, so your objects can fit perfectly. You also get a smooth shape so your objects get optimal protection.

2. Wire cut- Computer controlled wire cutting involves programming and auto CAD drawing. Customers can choose or supply the CAD drawings or one can be prepared as per the requirements.

3. Knife cut- Computer controlled knife cutting machines can serially produce multiple cut foam inserts from a single sheet of foam.

Many options are available in foam pads and inserts today. Custom designs are also possible through the easy-to use online applications. Foam inserts are indeed the most cost-effective techniques for protecting sensitive items.


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