Protect Your Equipment With Foam Inserts for Cases

Foam inserts for cases are a vital component of any packaging solution. They are essential for two reasons: protection and presentation. They not only keep the products safe and in the best possible condition, but they also allow manufacturers to display the items in a visually enticing way, encouraging customers to purchase.

Custom Case Company produces tailor-made soft-sewn bags and hard-carrying cases equipped with high-quality foam case inserts. Our products have proven beneficial for storing instruments, sports equipment, medical devices, electronics and computers, lighting systems, and various other applications.

What Are Foam Inserts for Cases?

Foam inserts are cutouts added to cases and packaging materials to protect goods in transit and storage. They also function as shock absorbers, soaking up and dissipating the force of an impact. Case foam inserts are also helpful in organizing and presenting equipment professionally and neatly.

Foam inserts for cases are used for small, fragile items and bulky products, such as camera equipment and electronic devices. To create smooth and precise cuts with the exact product measurements, manufacturers usually use computer numerical controlled (CNC) machining. This method allows each piece of equipment to have a distinct space, effectively making several custom compartments within a single case.

What Are the Benefits of Foam Inserts for Cases?

Case foam inserts provide safety for medical, electronic, military, or camera equipment and other delicate applications. Here are five other benefits of using foam inserts for packaging:

Provide Exceptional Protection

The main advantage of foam inserts for cases is protecting the equipment during transit — from production to the final location. It is also excellent for absorbing shock and preventing movement, which keeps the contents in perfect condition. Case foam inserts also help improve brand reputation by reducing damaged goods, leading to increased customer loyalty and repeat sales.

Custom-cut foams with specific dimensions are necessary to ensure that the contents of your case will remain intact. Moreover, calculating the correct foam performance (thickness, material, density, and design) helps ensure that packaging inserts are fully optimized for damage prevention.

Make Packaging Quicker

Packing and unpacking goods can be time-consuming, but case foam inserts can expedite the process. Since foam inserts for cases provide a dedicated space for each component of your product or equipment, packaging becomes more efficient. There is no need to meticulously wrap and pack items and parts, as the foam compartments also serve as protection. Moreover, it is easy to spot whether components are missing because you will quickly see empty slots in the foam inserts.

Save Business Money

Using foam inserts as a packaging alternative when delivering items can reduce expenses by streamlining the packaging process and safeguarding your equipment. However, using ill-fitting cases and foam inserts may result in more damage. To ensure that you get the best value for your money, it is crucial to carefully select a supplier with state-of-the-art manufacturing capabilities and top-notch attention to detail. Investing in a partnership with a reputable service provider will get you expertly-made custom foam inserts that protect your products and your business money.

What Are the Different Types of Foam Inserts for Cases?

It is vital to recognize and prioritize the equipment’s dimensions and requirements to select the correct type of foam inserts for cases. Whether it be quality, durability, cost, or appearance, different kinds of foams provide varying advantages and disadvantages.

The following are three of the most commonly used foams for creating case inserts:

Polyethylene Foam

Polyethylene foam is a long-lasting, lightweight material that is easy to manufacture. It is non-abrasive, non-dusting, and offers excellent impact protection for the case’s interior. It is also resistant to mildew, bacteria, mold, rot, moisture, and chemicals. These characteristics, combined with its additional vibration-dampening and insulation properties, make it suitable for packaging heavier items and material handling applications.

Polyethylene foam possesses load-bearing characteristics, allowing manufacturers to utilize thinner and smaller amounts of foam while providing excellent protection and durability. This can substantially lower packaging costs and space and storage requirements.

Cross-Linked Polyethylene Foam

Cross-linked polyethylene foam (XLPE) is widely regarded as the best protective packaging foam available. It is known for producing long-lasting and highly durable inserts. It is also considered to be the most aesthetically pleasing of the foam families and can protect class “A” surfaces. Lastly, XLPE has previously been utilized as foam inserts for medical equipment and sales presentation kits.

Polyurethane Foam

This open-celled foam is generally used in the packaging industry to protect lightweight, delicate equipment and products with high fragility and lower drop height limits. It is commonly used in medical packaging where abrasion resistance is necessary. Moreover, polyurethane foam offers excellent cushioning at a low cost and is easily molded or cut to fit specific applications. It is available in various densities and colors in two primary types: polyether and polyester.

How Are Custom Foam Inserts for Cases Made?

Creating custom foam inserts is more complex than it seems. Making a mold for small parts and attachments without the actual item or product is challenging. Here is the general process for cutting custom foam inserts:

Identifying Size Requirements

First, the manufacturer arranges the equipment with at least 0.75 in. between each piece and around the edges. Next, note the smallest area that will accommodate everything before measuring the tallest part of the equipment. Finally, at least 1.5 in. is added to that measurement to get the case’s minimum internal height.

Finding the Right Foam

Choosing the most appropriate foam for the application is critical. For example, polyethylene foams are best suited for heavy equipment and products, XLPE foams are ideal for improving aesthetics, and polyurethane foams are particularly fit for lighter and more delicate items.

Choosing a Case

Select a case that fits both the equipment’s exterior and interior dimensions. Custom Case Company offers a diverse range of high-quality cases categorized by type and application. Our products range from hard shipping to carrying and can be used for various purposes, including storing musical instruments, medical equipment, computers, electronic devices, and the like.

For transport cases showing a camera and additional batteries, three pieces are required: two relatively thin slabs inside the lid and base and a thicker block between them. To calculate the thickness of the top and bottom pieces, the case’s internal height is measured. Then, you subtract the height of the largest piece of equipment and divide by 2. Lastly, 0.5 in. is added to each piece to properly grip the equipment when the case is closed.

Cutting the Foam

When cutting the foam, there are different tools to choose from, each with its benefits and consequences. While there are several everyday items anyone can use to attempt to cut foam and shape it as case inserts, these usually result in inaccurate and substandard results. At Custom Case Company, we use waterjet or CNC die cutting to create uniform cuts that follow the customer’s specifications.

Choose Custom Case Company for High-Quality Cases

Since 1994, Custom Case Company has been making cases for various applications across different industries. We take pride in our versatility and attention to quality as we provide our customers with custom-made products unique to their requirements. Our staff’s adaptability also allows us to respond quickly to urgent requests while maintaining top-notch quality standards.

Contact us now for more information, or request a quote today!