Custom Foam Inserts

How can we make custom cases that safely cradle everything from sensitive electronic equipment to rugged tools? Part of the secret is the foam we use to customize the interior of many of our cases.

Foam Customization Methods

Depending on the application, quantity and complexity of your equipment, we can use one of several different methods to deliver a customized case interior.
Die-Cut Foam
Die-cutting foam uses a custom form, or die, to cut the foam to the shape of your equipment. Die-cut foam can be very cost-effective at larger quantities, and we operate a wide range of die presses to give our customers a full range of customization options.
Water Jet Cut Foam
Our large-scale water jet foam cutter uses a high pressure stream of water to cut precise shapes in foam. This foam customization method is ideal for either large or complex foam pieces, which can be cut to precisely match 3D CAD/ CAM models of your equipment.
CNC Routed Foam
Our 4-axis CNC foam routing machines use high speed rotary cutters to remove foam material and deliver precise, accurate custom foam interiors. Taking input directly from a CAD program, CNC routed foam is an excellent option for making one-off cases, or developing initial prototypes for a larger run.
Fabricated Foam
Foam fabrication is simply the industry’s term for the shaping of foam through cutting, grinding and bonding foam together to create custom shapes. Using our foam fabrication facilities, we’ll customize your case’s interior foam to match the shape of your equipment.

Types of Foam

1.7 Polylam

A resilient closed cell polyethylene 1.7 pound per cubic foot density foam produced with layering technology. Has unique cushioning characteristics due to its layered structure.

Convoluted Foam

Convoluted foam is sometimes called “egg crate foam”. It is a versatile polyurethane foam used commonly as lid foam in injection molded cases.

Anti-Static Polyethylene Foam

Anti-Static Polyethylene is a high performance cushioning foam for heavier items that also provides anti-static properties for sensitive electronic parts and products.

Anti-Static Polyurethane Foam

Anti-Static Polyurethane is a high performance cushioning foam for lighter items that also provides anti-static properties for sensitive electronic parts and products.

EPE (Expanded Polyethylene) Foam

EPE foam is a closed cell beaded polyethylene which has a low weight, high strength ratio. It is a semi-rigid, non-cross-linked and closed-cell type of polyethylene foam. Cellu-Cushion- 6.0 pound PE. This 6 pound polyethylene foam is generally added as a thin top layer to custom foam cushions to add color and strength to the cushion. We can also use this foam to put colored logos in foam cushions. Stock colors are Blue and Red but other colors are available. (Minimum quantities may apply)

Cellu-Cushion- 6.0 pound PE

This 6 pound polyethylene foam is generally added as a thin top layer to custom foam cushions to add color and strength to the cushion. We can also use this foam to put colored logos in foam cushions. Stock colors are Blue and Red but other colors are available. (Minimum quantities may apply)

Cross Linked Polyethylene

Closed cell, with a smoother surface feel than regular polyethylene. Good for applications outside the normal PE foam area, replacing materials such as vinyl foams, neoprene, natural rubbers, polystyrene and other polymeric materials. Color charcoal gray.

Polyurethane

Softer, open-cell foam, best for lighter weight, sensitive equipment with high volume-to-weight ratio. Color charcoal gray.

Polyethylene

Firm, closed cell foam, best for general use with heavier equipment. Color charcoal gray. Meets MIL P 26514, type 1, class 2 specifications.

Let Us Help You Find the Right Foam

Choosing the right foam for your application can be a complex process. The good news is that you don't have to. Just fill out our contact form - and we'll put our engineers to work for you.

Picking the Right Foam

Calculate the Foam Load

To calculate the foam load for your equipment, you need two numbers. The weight of your equipment, and the surface area of the side of your equipment that will be resting on the foam.

Once you know that information, you can use the following formula to calculate your foam load:

Equipment Weight (in lbs.) ÷ Side Surface Area (in ft2) = Foam Load.

The process will be repeated for each side of your equipment to make sure your case is providing appropriate protection no matter how it’s sitting.

Determine the Proper Foam Type & Density

Different types of foam have different characteristics and applications. Once our engineers have determined your equipment’s foam load, they’ll evaluate the proper foam type and density.

Assess Your Equipment's Fragility

Different equipment have different levels of fragility. In the industry, we assign a number to each piece of equipment, called a “G-Factor,” directly related to the g-forces that a piece of equipment can experience without sustaining damage. The more data we have about a piece of equipment, the more accurate a g-factor we can assign to it. In some large-scale projects where obtaining an accurate g-factor is critical, we might even use laboratory testing, where equipment is subjected to a series of gradually stronger impacts to precisely determine its g-factor.

Fragility Sample Equipment G-Factor
Extremely Fragile Pre-aligned scientific equipment, delicate aeronautical equipment, precision test instruments 15-25
Very Delicate Pre-aligned scientific equipment, delicate aeronautical equipment, precision test instruments 25-40
Delicate Computer equipment, electronics, aerospace accessories 40-60
Moderately Delicate LCD Televisions & Monitors, Video Cameras & Photography Equipment 60-85
Moderately Rugged Mechanical Equipment, Household Appliances 85-115
Rugged Hand Tools, Industrial Machinery, Construction Equipment 115+

Assess The Handling Requirements

Equipment that’s going to be stored in a climate-controlled storage room has very different handling requirements than equipment that’s going to be regularly tossed from the back of a truck, into the hull of a canoe.

Putting It All Together

By combining the equipment’s anticipated drop-height (from our expected handling requirements) with its weight and foam-load, we can determine the appropriate depth and type(s) of foam to reach a safe g-factor for that equipment.

Depending on the size and shape of your equipment, there may be several different ways to achieve a safe g-factor, and our engineers can help you decide the best way to reach that goal for your individual needs.

Let Us Build You The Perfect Case