If you need to protect your expensive, fragile, or business-critical tools, products, and equipment, custom foam inserts are essential.
Foam inserts are custom-cut foam placed inside protective cases, returnable containers, trays and packaging boxes. They secure items, cushion them from damage, shock and vibration, and can help with organisation and presentation. Typically manufactured from Plastazote® or similar closed-cell foams, they are popular for protecting tools, high-value components, medical equipment, electronics and specialist equipment.
At Polyformes, we are one of the UK’s largest foam insert manufacturers. Our in-house designers and cutting-edge foam conversion equipment enable us to produce foam inserts tailored precisely to your requirements.
Source custom foam inserts for cases (or any other bag or container your business uses) that are a perfect fit for your products and equipment.
Alongside the case insert options, you can source a wide range of bespoke foam inserts for boxes and packaging applications.
By working with Polyformes to source your foam inserts, you benefit from:
Businesses and individuals primarily use foam inserts to protect high-value, important or fragile items during storage, handling and transit. Their use is widespread across applications such as engineering (service technicians, field staff, etc.), military, automotive, aerospace, medical, electronics, and even sales presentations (in sample cases).
The specific application determines the type and grade of foam used to manufacture an insert. For high-performance case inserts, a closed-cell polyethene such as Plastazote® is typically used. For single-trip applications and corrugated box inserts, a lower-density material such as Stratocell® or Ethafoam® is more suitable.
Foam converters, such as Polyformes, use a range of techniques to manufacture foam inserts. These include CNC routing, waterjet cutting, lamination and layering, die cutting, laser engraving, and even printing.
Pick-and-pluck foam inserts are a type of foam pre-scored into small cubes. The end user can then easily remove sections of foam to create a semi-bespoke insert. While this is OK as a low-cost option for one-off applications, they are time-consuming to create and provide significantly less protection than custom foam inserts.
We don’t just manufacture foam inserts – we gain a detailed understanding of our business and challenges before proposing a cost-effective solution that does exactly what you need.
Understanding
We discuss your requirements with you, gaining a full, detailed understanding of your project.
Develop
Using your products or CAD data, we develop a solution using appropriate materials.
Test
We provide pre-production samples for testing and assurance on fit and quality.
Manufacture
We manufacture your inserts in-house at our specialist foam conversion facility.
Support
We forge long term relationships, providing ongoing support and assistance.
Our vast experience in designing, manufacturing and supplying both foam inserts and the accompanying protective cases, means we can offer your business several significant advantages.
UK manufacture
Short lead times
Single source
Advice and guidance
Vast experience
Sustainable at heart
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Send us a message
If you need high-performance, single-trip packaging to ship your valuable or fragile products, custom foam end caps are the most cost-effective option. Please contact a member of our team for a free consultation and quote.
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Our experts
The information on this page was written and checked by our team of packaging experts:
Technical Sales
Emma Atterbury
[email protected] | 01525 852 444
Quotes / Pricing
Amy Donnelly
[email protected] | 01525 852 444
Customer Service
Ian Rumsey
[email protected] | 01525 852 444