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Different Methods For Manufacturing Custom Foam Interiors for Transit Cases

Like so many other things, shipping cases, carrying cases and custom cases can all be manufactured using a variety of different materials based on your durability needs. For maximum protection custom foam combined with the right case construction is an integral part of the packaging of your valuable and sensitive items.

By understanding what each of these different foam manufacturing methods has to offer, you can gain a better understanding for which type of custom foam is right for you and your packaging needs. Different methods for manufacturing custom foam – along with their best use – are outlined below.

Die-Cut Custom Foam

Die-cutting is used to create large quantities (typically over 25) of uniformly designed products. If your organization is going to require a large number of a particular case for packaging your product for sale in the industrial or retail markets, the company that you contract to manufacture them may very well use die-cutting for its efficiency and cost saving benefits.

Band Saw/Hand-cut

Band Saw is an excellent single piece cutting method. It’s perfect for quick prototypes with minimal detail and few cavities. Typically the pattern image is drawn on the underside of the foam then cut with a band saw with a special low dust foam blade. A skilled technician cuts each cavity entering from an outer wall of the foam following the pattern and exiting back through the original entry point. Once the cutting is complete the entry point is glued back together.

Water Jet Design

Water jet cutting is a popular manufacturing method that involves using a high pressure jet of water to perform precision cuts and designs. If you can draw it with CAD you can cut it. Water jet is very cost effective for quantities under 25. The huge advantage is that it can cut extremely detailed configurations, very small cavities and a large number of cavities with ease. Whereas previously discussed band saw is time consuming, tedious and very difficult when it comes to tiny details. Water jet also directly penetrates the foam eliminating the entry point from a side wall creating a week spot. The end product is uniformly strong and exceptionally durable and presents well for sample and tradeshow needs. The water jet process does have a drying time that varies on the type of foam and the fabricators drying procedure and should be considered when calculating receipt of goods deadlines.

Contour Saw Manufacturing

Many manufacturing firms – and custom foam designers – use contour saws for their flexibility and ease of use. Contour saws allow the designer to apply razor sharp precision to their foam. Contour Saw is also an excellent choice for small quantity production. While the detail capabilities are better than band saw it does not have the capability that water jet has. One of the big advantages is that you don’t have to deal with drying of the foam. Contour saw may be limited to foam thickness.

CNC Router Machining

A CNC (computer numerically controlled) machining tool is a highly automated system that utilizes CAD designs and computerized data configurations, as opposed to manufacturing manually. The computer driven machinery results in consistent and uniform quality and design.

CNC Router is best suited for firm foams.

Hot Wire CNC Foam Cutting

CNC Hot wire foam cutters are popularly used in manufacturing to achieve precise, customized results from semi-rigid foams. Often used in fabricating architectural products such as crown moldings and columns, hotwire foam cutters work well with EPE and EPP foams.

Self-Configuration Options

When time is of the essence and your presentation and protection needs don’t require custom foam, self-configuration options like using a utility knife or electric knife to cut solid layers of foam or using pre-cut “pick 'n' pluck” foam are a practical approach.

Considering the preceding information, when it comes to protecting your important equipment and products you have many foam options. Today's shipping case interiors can be designed using many truly sophisticated methods of custom designed foam, creating the most formidable kinds of protection and security for even the most discerning organizations.

About the Author

The author is an authority in the field of manufacturing shipping cases and military cases. Their website is an excellent resource regarding the advantages of utilizing safe shipping cases.

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