How Packing With Foam Inserts Can Result In Better Protection And Stabilization

Industrial & Manufacturing Blog

Foam inserts are used in many different ways and are made from low and high-density foam, depending on how they will be used. Often foam inserts are precut for the specific job they will do, but they are also available as single sheets of foam that you, or a foam manufacturer, can cut to a particular size for custom applications.

High-Density Foam

Foam inserts made from high-density or closed-cell foam are rigid inserts that hold their shape well and may be used in packaging heavy items for shipping. Because the foam is not overly pliable, it can protect the item you are shipping by holding it solidly in place and absorbing impacts from the outside. 

You will often find this foam used in boxes with small appliances, computers, or electronic components that must be secure and arrive without marring or damage. In some situations, the foam insert is made in layers, using multiple thinner layers of the material and gluing it together, then cutting out the shapes needed with a special press that has a blade on it to cleanly cut all the layers of foam at the same time. 

This creates a highly uniform foam insert block that you can use inside a box or case to put components into it for shipping or transport. The foam can be white, black, or any color the manufacturer wants to make, but the material is typically very similar in the variants used. 

Low-Density Foam

Low-density foam inserts are softer and have a less compact cell structure, so the foam tends to give more. This is also sometimes called open-cell foam, and it is often used to create inserts that need to conform around the object in the box or case. 

One example of this is a gun case with a low-density egg crate foam insert. The gun is laid in the case then held in place as it is compressed between the top and bottom. This same principle is often used for camera gear, sensitive equipment, and shipping products.

When used in shipping, the foam inserts will cradle the item in the box and sometimes allow slight movement to protect the product against vibration. If the box is dropped, it can also allow additional protection because the foam insert absorbs most of the energy from the impact and shields the item inside it.

The low-density foam inserts can be cut to specific shapes, much like the other foam inserts used in similar ways. When appropriately layered, they can create a protective envelope around the item to ensure no damage comes to it. If you have a custom application in mind, you can purchase these foams at some local craft stores and cut them to make your own foam inserts by fitting them to your needs and layering them into a case or box.  


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