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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 create a more professional appeal. 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 tech, gaming, automotive and much 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 this foam product. If you’ve got items in need of protection/presentation, contact one of our experts to learn how to order your custom foam inserts.

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. Simplistically speaking, it works somewhat like a cookie-cutter does.

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, for example.

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.

DIY Foam Trays

Some people choose to make their own DIY foam inserts. Of course, we must stress the importance of sensible safety procedures to anyone that chooses to do so. Any modifications you make to foam purchased from us is done so at your own risk.

Our HLB (High Load Bearing) polyurethane packaging foam is a common grade 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.

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.

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 highly clean finish like some industrial conversion techniques can. With that said, we have personally seen many effective and professional-looking foam inserts that have been cut by hand.

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Contact Our Team

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

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