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Our Tips For Designing Custom Protective Foam Inserts

Is there anything worse than opening a cardboard box after you’ve moved, just to find that your valuable items have been damaged in the process? Maybe you’ve pulled down a bin of holiday decorations, opened it up, and discovered that your fragile ornaments have shattered – if this sounds like you, then it might be time to look into a custom foam insert. Luckily, the process of finding the perfect inserts is much simpler than you’d think! In this post, we’ll teach you everything you need to know about designing personalized foam inserts. Your items will soon be secure and protected, so you no longer have to worry about damaging those special pieces!

Custom EPS Foam Packaging Blocks
Custom Packaging Blocks

Custom Foam Insert Design Process

Before you start picking out your foam or placing a special order, you’ll need to consider a few different components of the objects you’re needing to store. Understanding these aspects will help you determine which kind of foam is right for the job. Here’s what you need to know:

Consider Weight and Fragility In Custom Designs

When it comes to designing your foam inserts, you’ll want to begin by analyzing the weight and fragility of the items you’re wanting to protect. These are two of the most important components of your plan – the requirements your inserts will need to accommodate can vary depending on the items you’re working with. For example, you could be trying to store something lightweight and delicate, like decorations or other breakable household items. On the other hand, valuable equipment such as camera gear or musical instruments can be much heavier, so they’d require a different approach.

Now, you may be wondering: how does the weight of the item change the way you’d design the inserts? It comes down to the type of foam being used. For lighter, more fragile objects, you’ll most likely want to use polyurethane. This foam is specifically designed to protect delicate items that don’t weigh much, making it a good choice for this scenario. For heavier pieces, we always recommend selecting a more durable foam. In this case, using polyethylene for your custom foam insert is a better alternative, due to its firmness and increased density.

Account for Positioning and Cushioning Requirements

The other aspect you’ll want to consider when designing your foam insert is the positioning and cushioning requirements for the item(s). The whole point of creating custom inserts is to make sure your valuable objects are protected and secure, so you need to evaluate how you’d like the items to sit within the foam cushioning. Polyethylene is a solid choice because its firm, dense foam can withstand various chemicals and moisture over time without deteriorating. Plus, you can easily use this foam to create a custom insert that’s fitted to the measurements you need.

Custom Foam Insert Recommendations

Now that you know a bit more about designing foam inserts, we’re going to show you some of our favorite ways to protect valuables. Here are a few ways you can use your new inserts:

1. Camera Packaging
Every photographer knows how important it is to protect their equipment. Instead of throwing all your gear into a bag and hoping for the best, take advantage of the peace of mind that comes with having a personalized storage case featuring the highest-quality foam inserts. At Foam Factory, we’re able to create the custom camera packaging of your dreams using our special foam-cutting technology. Simply reach out to us with the dimensions you need, and our experts can get you started with your new storage solution.

2. Storing Breakable Decorations
When it comes to finding ways to store fragile items, such as holiday ornaments or other decorations, you actually don’t even need to order custom-cut foam. All you need to do is order a sheet of your foam of choice (in this case, polyurethane would be a good choice) and cut the foam yourself with an electric kitchen knife to fit your storage bin or container. Then you simply lay your decorations on top of the foam. If you’d like, you can even cut multiple pieces of foam to create cushioned layers for additional protection. If you don’t have time to DIY this project, don’t worry. You can always order custom-cut pieces from Foam Factory, too!

For more information on using personalized foam inserts for protective storage, check out our custom foam packaging page. As always, if you have any questions, please feel free to contact us.

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