Designing Custom Foam Inserts? Consider These 3 Things

Custom Case Design & Engineering


Have you ever opened a box after a move and noticed that a few delicate items are broken? Chances are these fragile items experienced some turbulence in transit, and without the proper protection in place, they shifted out of place and were damaged.

In an effort to avoid these same adverse effects, businesses rely on custom foam inserts to complement a durable exterior in product packaging. Whether included in stock cases or custom-designed solutions, these inserts deliver precise protection for delicate products — all while distinguishing your brand in a positive manner.

While you think about custom foam inserts for your own applications, here are three considerations to help guide the design process.

The Weight & Fragility of Your Product

Weight and fragility are two critical components when designing custom foam inserts for cases. In some scenarios, you may be dealing with delicate, lightweight products — a list that could range from hearing aids to pens. In terms of the type of foam used, polyurethane is likely a good option, as it is designed specifically for fragile products that don’t weigh much.

If we’re talking about a 70-pound airplane brake, you’ll need a more durable, reinforced solution — from the inside out. Custom foam inserts made from polyethylene, a firm dense foam made for heavier products, is a viable alternative.

Positioning & Cushioning Requirements

Imagine a situation where a sales team meets with doctors to pitch their spinal implant products. If the case does not have proper compartments to house each product, its contents can become disorganized (and potentially damaged). This can make the presentation both less efficient and less professional.

From a positioning and cushioning standpoint, polyethylene is recognized for its use in custom foam inserts. That’s because this firm, dense foam can withstand moisture and chemicals, and thus won’t deteriorate from continuous use. These custom foam inserts can be fitted to the precise measurements of your product fleet, and be easily removed for presentation purposes.

The Branding Opportunities

While the exterior of your product packaging should begin your brand story, that’s not where it should end. From materials to colors, your custom foam insert should be thought of as an opportunity to further enhance your brand reputation and educate others about your products.

Let’s use the example of a medical device manufacturer who wants to refresh their display case for surgical products. A professional cherry-stained wood case can be paired with a custom foam insert that keeps products at the same height and includes photo-etched aluminum labels for each item. The same sophisticated style on the exterior of the case is clear on the interior.

As a leading provider of custom case solutions, Cases By Source has experience designing and manufacturing a wide range of cases from the inside out. Learn more about the approach we take here.


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