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.

Curious about the various ways we custom coat our foam inserts? Head on over to our video library to find out all about it.

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.

1.7 POLYAM

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.

XI-20 Irradiated Cross-Linked Polyethylene

Closed-cell, water-resistant, two-pound foam with an even smoother surface and smaller cells than chemically cross -linked polyethylene thanks to the irradiation process. Can be made into thinner sheets than other polyethylene foams, making it ideal for compact applications. Color: charcoal gray.

LET US HELP YOU FIND THE RIGHT FOAM

Choosing the right material for your custom foam inserts 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.

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