Custom Foam Inserts
Precision-cut foam cavities that absorb shock and hold high-value product immobile. EVA, EPE, PU, and PE foams cut to your exact geometry.
Why Custom Foam Inserts
When the product cannot be allowed to move
Foam is what you specify when damage in transit is unacceptable — instruments, electronics, medical devices, high-value tools. Unlike board, foam absorbs impact energy rather than just restraining movement, and a correctly designed cavity holds the product with zero play so it never builds momentum inside the box.
Foam choice is an engineering decision, not an aesthetic one. Density controls how much energy the foam absorbs before it bottoms out, and the right density depends on product weight and drop height. Under-specify and the foam compresses fully on impact and transmits the shock; over-specify and the foam is too rigid to cushion at all.
Specifications
Standard Sizes, Materials & Order Info
Foam types
EVA (dense, premium), EPE (light, economical), PU (soft, conformable), PE cross-linked, XPE
Densities
25-200 kg/m³ selected against product weight and drop height
Cutting
Die cutting, CNC routing, waterjet, and hot-wire for large profiles
Tolerance
±0.5mm CNC routed; ±1mm die cut
Colours
Black, white, grey, blue, red; custom colour at higher volume
Finishing
Velvet/flock lamination, fabric wrap, pull tabs, ribbon lifts
MOQ
300 pcs (lower for CNC-routed prototypes)
Lead time
12-20 working days including a fit sample
Built-In Advantages
What Makes Our Custom Foam Inserts Stand Out
CNC routing for complex geometry
Undercuts, varying depths, and organic shapes that a flat die cannot produce. Essential for instruments and irregular tools.
Density matched to drop testing
We select density from your product weight and expected drop height, then validate on a physical drop test rather than assuming.
Velvet and flock finishes
A flocked surface turns a functional foam block into a premium presentation tray — standard in jewellery, watch, and luxury electronics packaging.
Finger recesses and pull tabs
Small cut-outs or ribbon lifts so the product comes out easily. Without them, a tight cavity becomes frustrating to unpack.
Common Uses
Where Custom Foam Inserts Are Used
Start Your Project
Let’s Design Your Perfect Custom Foam Inserts
Request a Free Quote
More Custom Packaging Inserts