Description
Why choose our foam box inserts
Better protection for products
Foam box inserts protect products during shipping by absorbing impact and reducing vibration. Each cavity is cut with roughly 1mm tolerance, tight enough to stop movement without forcing the product in. Fewer damages means fewer returns, which is usually where the cost of good packaging pays for itself.
Custom-fit design
We size the insert against three things: your product’s dimensions, its weight, and how fragile it is. Fragility gets measured as a G-factor, the deceleration a product survives. Consumer electronics typically sit around 40 to 60 G. Precision instruments and glass can be as low as 15 to 25 G, and those need thicker foam and more of it. Getting this right also saves space, because over-specified foam wastes box volume and pushes up your dimensional weight.
Materials
We work with four foam types, and the choice depends on what you are protecting.
Polyurethane foam is open cell and soft, usually 1.2 to 1.9 lb per cubic foot. It conforms around irregular shapes and suits lighter, delicate items. Pink anti-static grade is available.
EVA foam is closed cell and firm, from 2 to 6 lb per cubic foot. It holds a crisp cut edge, resists moisture, and looks premium, which makes it the usual pick for tool cases and presentation inserts.
Polyethylene foam is closed cell and resilient at 1.7 to 2.2 lb per cubic foot. It handles heavier products and repeated impacts better than PU.
Conductive and anti-static foam protects circuit boards and components where static, not impact, is the actual risk.
Our 360 degree insert process
Our engineers design every insert in CAD and cut it by CNC router, die, or waterjet depending on the geometry. Complex shapes and undercuts go to CNC. High-volume simple profiles go to die cutting, which is cheaper per part once quantities climb.
Before production we can run drop test simulation and, where a retail partner asks for evidence, physical testing to ISTA 3A or ASTM D4169. ASTM D1596 evaluates cushioning performance.
We do not sell inserts in isolation. The insert gets designed against the outer carton you are using, or we quote both together, because custom product boxes need inserts that fit the product and the box to provide proper protection.
Industries we work with
Electronics and technology, where components need anti-static protection alongside impact cushioning. Medical devices and diagnostics. Industrial tools and calibration equipment. Cosmetics and fragrance, usually glass. Firearms and optics cases. Jewellery and watches. Automotive parts.
Sustainable packaging
We would rather tell you what actually recycles than put a green label on everything.
Facilities can recycle polyethylene foam, which uses LDPE, resin code 4, where they accept it.US curbside programs rarely accept polyurethane and EVA, making recycling these materials much harder and preventing packs from carrying a recycling claim. If a plastic-free insert matters to you, molded pulp and die-cut corrugated fitments do the same job for many products, and both go in the paper stream.
CNC nesting reduces offcut waste on every sheet we cut, and right-sizing the insert cuts material and freight together.
Full service
Before production, we assess your current packaging, build 3D models and virtual prototypes, run protection simulation, and advise on material choice and where costs can come out.
During production you get a named project manager, quality reporting as the run progresses, coordination across multiple pack formats for a full product line, and scheduling built around your launch date.
After production we help with delivery routing, supply quality documentation, track how the pack performs in the field, and feed that back into the next revision.
Getting started
Three steps.
First, tell us about the product and what it needs to survive.
Second, we send a custom insert design with a 3D view for you to review.
Third, you approve a sample and we move to full production.
Our low-MOQ ordering starts custom foam inserts from 100 units, and standard production runs about 7 to 10 business days after sample approval. Book a one to one call with our team and we will work out the right foam, density and thickness for what you are shipping.
Multiple Packages provides custom foam box inserts tailored to your product’s protection and packaging requirements.
