Custom Foam Inserts: Design Steps for Parts Built to Arrive Perfect

• Polyethylene (PE): closed-cell, firm, holds shape through repeated use. The workhorse for industrial parts.
• Cross-linked polyethylene: finer cell, smoother surface, cleaner look. Good for painted or polished parts.
• Polyurethane (PU): open-cell and soft. For light, delicate items.
• Anti-static foam: pink or black foam for electronics and circuit boards.

1. Weigh and measure the part. Record dimensions, weight, and the surfaces the foam will touch.
2. Mark the fragile points. Note sharp edges, finished surfaces, and anything that bends.
3. Define the trip. Parcel shipments face higher drop heights than pallet loads. Returnable cases face hundreds of trips.
4. Pick foam type and density. Density is measured in pounds per cubic foot (pcf). Your supplier uses cushion curves, charts of how each foam absorbs shock at a given load, to match density to part weight.
5. Lay out the cavities. Plan pockets for each part, plus finger cutouts so packers lift parts out fast.
6. Size the box around the insert. Design the foam and the box together. Post 2 covers the box steps.
7. Build and test a prototype. Pack real parts and run drop tests from the heights your route sees.
8. Approve the spec. Lock foam type, density, dimensions, and cavity drawing on a written spec sheet.

Track damage claims on one SKU for 90 days. Multiply claims by the cost of each replacement part, reshipping, and the hours spent handling the claim. Compare the total to the cost of a foam insert per shipment.

Ship a part with a history of damage?

Send us the part and a damage photo.

We will design the insert and the box together.

S&S Incorporated · Packaging made easy since 1965 21300 St. Clair Avenue, Cleveland, OH 44117 216-383-1880 · info@sspkg.com · www.sspackaging.com Monday–Friday, 7:00 AM–3:30 PM