Custom foam inserts cut to size
If you or your business have tools, equipment, or products that simply cannot be damaged, you need custom foam inserts.
Foam inserts are used within cases and other packaging to protect contents from damage. Typically using Plastazote material, foam inserts are cut to the size and shape of specific items. Custom foam inserts both hold items in place and cushion them from shock, impact, and vibration.
At GWP Protective, we have been providing expert foam conversion services for more than 30 years. This includes manufacturing custom-cut foam inserts for a range of applications and industries. We are also one of the few UK companies using advanced software to precisely calculate the optimum foam thickness, density, and grade for specific tools and equipment.
Foam inserts for cases
Businesses and professionals primarily use custom foam inserts within protective cases. Our foam inserts for cases are precisely tailored to be a perfect fit for your products and your chosen case or container.
Foam inserts for boxes
Besides engineered foam for cases, you can also source a range of foam inserts for boxes from us (suitable for high volume and single trip applications).
Other custom-cut foam inserts
Custom-cut foam inserts are suitable for several other applications, including retail and presentation packs, returnable and supply chain packaging, tool control, and more.
More info
Foam inserts are surprisingly versatile in the applications to which they are suited.
This includes everything from foam inserts for toolboxes that quickly help to identify missing equipment to simple case lining. Their most common use, however, is within extra tough moulded protective cases to provide exact levels of cushioning from mishandling.
At the other end of the scale, the precise nature and high-quality finishes can make foam inserts an innovative and distinct way to differentiate your brand. This can allow for enhanced presentation of product samples in sales pitches or even drive revenue in sectors where added-value packaging is essential.
Plastazote foam inserts
Plastazote is unique in providing superb cushioning performance and a high-quality appearance.
It is well known for being lightweight, tough, flexible, moisture-resistant, chemically inert and resistant to oils, solvents, dilute acids, and UV light. It is also available in many colours, meaning you can easily match your business’ branding or specific product ranges.
Besides this, specialist foams, such as conductive, static dissipative and fire-retardent, are all available in the range.
Using Plastazote, your engineered foam inserts significantly reduce the effect of shock and vibration on any delicate, highly calibrated or valuable items during transportation and storage.
Custom foam insert FAQs
What are foam inserts used for?
Although typically used to cushion tools, equipment, or products within an outer case or packaging—which prevents damage in transit—foam inserts can be used for a wide range of additional applications. These include aiding the retrieval of items, presenting samples, and luxury packaging.
Are foam inserts for use in boxes or cases?
For protective cases, including waterproof, aluminium, or custom-built options, Plastazote® foam inserts are the best option. These inserts are also suitable for sample presentation cases. However, foam inserts using Stratocell or Ethafoam materials are widely used in single-trip corrugated packaging.
What colour foam inserts are available?
Plastazote® comes in more than 20 colours, allowing you to choose a shade that closely matches your company’s logo and/or branding. Please note, however, that not all colours are available across all grades.
I've seen two-tone foam inserts – how are these made?
Using layers of different-coloured Plastazote® can create foam inserts with a unique and attractive appearance. This is most commonly seen with black or dark foam laminated on top of a contrasting colour. When machined, the brighter colour underneath shows through to create a striking visual effect (which can also help with identifying missing parts or equipment).
What is a shadow board?
A shadow board is where different-coloured foams are layered on top of each other, with any recessed pockets being a different colour to the foam on top. Apart from the improved aesthetics, this can help identify parts that have not been returned to their specific place within the insert, as the area of brightly coloured foam is visible at a glance.
How can bespoke foam inserts protect my items?
Pre-cut foam inserts protect items during transit or handling by providing cushioning within the outer case or packaging. Not only does this stop the contents from colliding with each other, but also with the internal walls of the container. Taking this one step further, some foam converters can calculate the exact levels of foam required to absorb specific levels of shock or impact. Engineered foam inserts can, therefore, offer a genuinely bespoke and optimised level of protection for your items.
How do I choose an exterior case for use with my inserts?
Besides foam inserts, GWP can also offer your business a wide range of exterior case options. For example, waterproof cases are ideal for heavy-duty uses, whereas lightweight plastic sample cases are more suitable for less demanding applications. Other options include metal, custom-built flight cases, plastic tote containers, and even cardboard boxes. One of our experts can offer guidance on the best choice for your business.
What are pick-and-pluck foam inserts?
Pick-and-pluck foam inserts are pre-scored, typically into 1 cm cubes, which the end user can remove to create a semi-bespoke insert. Typically supplied with waterproof cases such as Peli or Explorer cases, these are a good choice for a one-off project (e.g., hobby equipment, camera cases, and so on). However, for industrial applications, we would always recommend bespoke foam inserts.
Custom foam insert manufacturers
At GWP, we are one of the UK’s largest independent foam converters. As such, working alongside our experts when sourcing your foam inserts can provide your business with a wealth of benefits.
For example, you can liaise with our experienced design team, using the latest software and performance models, to accurately engineer the precise level of cushioning required for a specific product or item.
This approach significantly reduces the potential for damage to the packaged article or, in many cases, completely eradicates it.
Source case and foam insert together
Plus, as one of the largest independent UK suppliers of transit and equipment cases, we can design your foam inserts to work seamlessly with any exterior case, container, or even cardboard packaging.
This significantly improved compatibility between case and foam allows for protection from vibration, water, and dust and provides highly engineered, precise levels of protection.
Whatever your application, you can request free impartial advice at all stages of your project, benefit from competitive pricing to suit practically any budget and volume, and have your inserts manufactured using the latest technology and equipment.
Contact us today to see just how good your custom foam inserts can be.
All foam options
Protective cases
Other outer packaging
Related guides
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01722 416 440
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protective@gwp.co.uk
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