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Custom Foam Inserts – Factory Made & DIY Foam Trays

custom foam insert trays

If you’re looking to display, secure and/or protect items with custom foam inserts, we can provide the foam you need to create them. In some circumstances, we can even use our advanced foam cutting machinery to create precision-cut custom foam inserts for you.

Why Custom Foam Inserts Are Beneficial

Foam inserts help to keep items safe and secure but can also help to give certain pieces a premium flourish. Whilst custom foam trays are great for protecting your items of choice, they’re also perfect for presentation pieces. In the past, we’ve created custom foam inserts for promotional materials from a variety of industries including in tech, gaming, automotive and more.

Just a few examples of items that can benefit from a custom foam tray include – tools, technical equipment, assembly parts, electronics, presentation pieces and collectors’ items. But that’s not all! There are so many unique items that can benefit from a foam insert. If you’ve got items in need of protection/presentation, read on!

Factory Made Foam Inserts

Foam inserts made in factories are sometimes created through a method called die-cutting. This method uses a specialised die cutting press to create an intended shape. Simply speaking, it works somewhat like a cookie-cutter.

The desired shape is turned into a template called a die which is used to replicate the cut of the foam. The machine then exerts a large amount of force between the foam and the die in order to create a given shape. The nature of this foam conversion technique allows the manufacturer to accurately and quickly replicate the foam insert as many times as required.

Due to initial setup times and the costs involved, this technique is not recommended for one-off orders. It’s more suited towards larger orders of foam inserts used for higher-end commercial items, presentation pieces, or intricate/fragile industrial parts.

There are also other methods to create foam inserts. This includes using a CNC router to machine a given shape. Our factory is equipped with both of these machine types, along with many other types of foam cutting machinery.

If you’re interested in ordering custom foam inserts from GB Foam, our team of experts will be happy to answer any questions you may have. Get in touch by email sales@gbfoam.com or by calling 01494 441177.

DIY Foam Trays

Some people choose to make their own DIY foam inserts. These can be made using high-quality packaging foam, closed cell foam and more. If you’re making any modifications to foam you should take all necessary precautions to protect yourself.

HLB Packaging Foam

Our HLB (High Load Bearing) polyurethane packaging foam is a popular choice for DIY foam inserts. Manufactured with protection in mind, this high-quality foam offers superior shock and impact absorption to help protect your goods from damage. Our packaging foam sheets are available in two sizes 230 x 100 cm and 230 x 200 cm. These can be easily cut down to size at home. The thickness of our HLB packaging foam sheets ranges from 6mm up to 100mm. If you would like to learn more about this foam, head over to our dedicated page or contact our team.

Plastazote LD33 Closed Cell Foam

Similarly, another choice for heightened protection is Plastazote LD33 closed cell foam. Plastazote offers good levels of shock absorption. It is also resistant to many chemicals, is water-resistant and has good UV stability. We offer Plastazote foam sheets in both black and white. Each sheet measures 200cm x 100cm and can easily be cut down to size at home. Thicknesses range from 5mm all the way up to 50mm. Plastazote is suitable for many different applications, not just packaging. If you would like to learn more about this unique closed cell foam, please visit our dedicated page or get in touch with our team.

Making a Foam Insert

Once you have selected a foam grade you are happy with, plot out the shape you wish to cut out. A sharp blade (such as a scalpel) is required to make incisions in the foam and cut out shapes. Again, please exercise caution when using sharp objects so as to avoid injury.

Be aware, this method can sometimes take practice to get right. It is unlikely to produce a perfectly clean finish like professional foam conversion techniques do. However, with a steady hand, a bit of practice and the right tools, you’ll surely produce a DIY foam insert to be proud of.

Contact Our Team

If you’d like to know more about our custom foam insert services, please feel free to get in touch. One of our foam experts will be happy to offer advice about our services to help you find the ideal product for your needs.

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