Foam Inserts and Packaging

To round off cases and packaging perfectly, you also need to take a look at the inside: Individual foam inserts are the right choice for protection and organization. The precise fit of the cut-outs ensures that the items in the case do not slip and become damaged. Tools, components and other sensitive items are therefore optimally protected during transportation. Milled inserts are suitable for a wide range of industries and products. Whether sensitive electronics or weighty metal components: they are in good hands in foam or foam rubber.

We achieve the necessary precision and form fit using modern CNC milling machines. The advantage of this process is its cost efficiency, as no tools are required. Programming the milling machine takes little time and the process itself is almost completely automated.

Possibilities for Processing

We mill most of our foams to create precisely fitting molded parts and inserts. In addition, it is also possible to process the material with a water jet cutter in order to achieve a specific edge finish, for example. As a third option, we also work with hydraulic die-cutting machines, which can also be used to process foams.

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  • Ein Stapel von Schaumstoffen in verschiedenen Farben und Strukturen.

    Types of Foam

    One of the most important properties when choosing the right foam is the volume weight. This describes the density of the material and therefore its durability and quality. It is important to find the right balance between stability and lightness of the foam in order to produce the best-fitting insert.

  • Ein Shadowboard mit gefrästen Einsätzen aus schwarzem und grünem Schaumstoff.

    Shadowboards

    Inlays made of two-tone foam can be produced as so-called shadowboards, which are ideal for organizing tools, for instance, thanks to the increased contrast the material provides.

  • Ein Schaumstoffeinsatz in einem Koffer, der mit rotem Samt kaschiert wurde.

    Lamination

    To create a particularly elegant insert, the material can be laminated with various fabrics after cutting, for example colorful velvet or printed fleece. This makes the insert customizable and not dependent on the appearance and texture of conventional foam.

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Application for Foam Packaging and Inlays

The areas in which foam is used are as diverse as the materials and their properties. Inserts, packaging and inlays made of foams can be used in countless industries, and individual processing using milling machines sets almost no limits to the end product. We are fully familiar with the respective material and cutting pattern requirements.

Transport

Suitcases, flight cases, etuis, containers, cardboard boxes - foam inlays guarantee the safe transportation of a wide variety of items. Precisely fitting inserts and durable material also provide optimum protection for sensitive accessories on long journeys.

  • Ein Aluminiumkoffer mit einem schwarzen Schaumstoffeinsatz mit verschiedenem Medizinequipment.

    Medicine

    Instruments, Laboratory Equipment

  • Ein Koffer aus Aluminium mit einer gefrästen Schaumstoffeinlage für Ersatzteile einer Maschine.

    Machines

    Spare Parts, Accessories

  • Ein Koffer mit einer Schaumstoffeinlage. Der Koffer beinhaltet ein technisches Messgerät.

    Craftwork & Technology

    Tools, Measuring Devices

  • Ein Koffer mit einem Schaumstoffeinsatz für Kopfhörer und verschiedenes Audi-Equipment in einem Musikstudio.

    Music

    Instruments, Audio Equipment

  • Ein Waffenkoffer mit einem schwarzen Schaumstoff-Inlays, das genau auf die Umrisse der Waffe zugeschnitten ist.

    Military

    Guncases, Professional Gear

  • Eine Einlage für einen Spezialkoffer aus grauem Schaumstoff mit gefrästen Ausschnitten.

    Specialty Inlays

    i.e. for Precision Instruments

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Presentation

For presentations at trade fairs or customer pitches, made-to-measure inserts are ideal for conveying care and quality. The products are optimally protected and attractively presented at the same time. The foam inserts can also be used as advertising material or in product displays for high-end products such as watches and jewelry, as they can be elegantly laminated with various materials. The choice of antistatic ESD foam is particularly worthwhile for the presentation of electrical devices such as cameras or smartphones.

  • Ein grauer Präsentationskoffer, in dem viele Farbmuster in einem gefrästen Schaumeinsatz liegen.

    Samples

  • Ein Präsentationskoffer mit teuren Uhren in einer schwarzen Samteinlage

    Luxury Products

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Eine Werkbank mit einem geöffneten Schubfach. Darin liegt ein Shadowboard aus Schaumstoff mit verschiedenen Werkzeugen.

Drawer Inserts and Organisation

Foam inlays are a good choice to ensure that everything is in the right place at the right time. They can be used in drawers or cupboards for simple applications such as desk organization or for complex logistics optimization. Various utensils can thus be stored in the best possible way, whether in the office to keep the workplace perfectly organized or in the catering trade to keep cutlery and kitchen utensils to hand, to name just a few examples.

Eine schwarze Schaumstoffmatte, die auf dem Boden einer Autowerkstatt liegt.

Pads and Protective Mats

As a resistant and durable material, PE foam is also suitable for tasks with high loads. The material can be used as a support or protective mat in many areas. Foam is also suitable for such applications thanks to its resistant and durable structure, which also offers softness and elasticity. For example, foam is used in occupational safety or as a protective base for construction components.

Foam Packaging and Specialty Accessories

Foam packaging can take various forms to ensure protection against shocks and vibrations. Constructive packaging is particularly suitable for sensitive objects that need to be completely enclosed in a protective shell during transportation. Interlocked, glued or made from one piece, the foam surrounds the object on several sides to absorb shocks during transportation as effectively as possible. Antistatic foams with ESD protection are particularly suitable for electrical appliances such as TVs. In small format, distance pads can be used to place them between less sensitive components to prevent them from bumping into each other.

  • Ein Laptop in einem Pappkarton und einer Konstruktivverpackung aus weißem Schaumstoff.

    Constructive Packaging

  • Eine Reihe kleiner Schaumstoffwürfel zur Distanzierung von Transportgütern.

    Distance Pads

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Ein Musikstudio mit einer verkleideten Wand aus grauen Schaumstoff-Platten.

Application in Soundproofing

The strong insulating properties of foams also make them ideal for sound insulation. Recycled foam in particular is especially suitable for reducing noise due to its usually higher density. Foam panels are used in machine and engine housings or specific rooms, such as recording studios, large halls or even home cinemas. Currently, its use in the energy sector is also becoming increasingly important: for example, for the insulation of heat pumps, seals for electric charging stations or the noise insulation of wind turbine gearboxes.

Foam Materials for Inlays

Ein Stapel von verschiedenfarbigen Platten aus Polyethylen-Schaumstoff.

Polyethylene Foam (PE)

This closed-cell foam is probably the best-known option for packaging and cushioning material. Polyethylene is very strong and dense. This makes it suitable for durable cushioning and the transportation of heavier items. PE foam is also strong in thermal insulation and resistance to chemicals. Various special processing options are available to equip the material for special applications: antistatic, electrically conductive, flame-retardant, self-adhesive and other properties can be implemented.

Ein Stapel verschiedenfarbiger Platten aus Polyurethan-Schaumstoff.

Polyurethane Foam (PU)

This versatile, open-cell foam usually has a softer and more flexible structure. Depending on the density and area of application, the thermal insulation of flexible PU foam or the stronger mechanical properties of rigid foam may be preferred. There is also a distinction between ether-based foam (particularly insulating and water-resistant) and ester-based foam (resistant to light chemicals such as oils or soaps).

Ein Stapel von verschiedenfarbigen Platten aus vernetztem Polyethylen-Schaumstoff.

Crosslinked PE Foam

Crosslinked PE foam is one of the most widely used materials for packaging and cushioning. Compared to its non-crosslinked counterpart, the material is even stronger and more durable. It is also characterized in particular by high thermal insulation and resistance to liquids. This makes the material particularly suitable for demanding applications and transportation. Just like non-crosslinked PE, crosslinked PE can be processed in different ways, for example to achieve antistatic properties.

Ein Stapel von Platten aus recyceltem Schaumstoff. Die Platten sind grau und bunt melliert.

Recycling and Compound Foam

Despite the fact that foams are almost always made of plastic, there are sustainable options here too. Recycled foams consist of offcuts from conventional foams that are joined together to form new sheets. The material itself is also easily recyclable and can be reused several times. The recycling process usually gives the material a higher density, making it harder and more stable and providing good sound and vibration damping.

Ein Stapel von verschiedenfarbigem Schaumstoff, eine Flasche mit gelbem Öl und eine Raps-Blume.

Biobased Foam

In order to make the production of foam as sustainable as possible, biobased resources can be used. These replace a certain percentage of the plastic content in the foam and thus reduce the impact of fossil raw materials. Substitutes can be sugar cane or vegetable oils from rapeseed, for example.

Your Project

Our work is far from finished with a completed foam insert. We supervise projects from the first sketch through to assembly - complete solutions for cases and molded parts are our specialty. We take care of the selection and procurement of materials, the creation of cutting patterns and the shipping ourselves, or work together with your own experts to optimally fulfill your needs.