Reviewing Different Materials for Custom Foam Inserts

If you’re experienced in traveling with fragile items of sensitive equipment, you already know what it takes to keep them safe: a sturdy case to protect the pieces from outside damage and proper filler materials to protect from jostling. Those filler materials are more often than not custom foam inserts because they are the best means of protection and organization, regardless of what you’re transporting. You may be surprised to hear that there are a variety of materials used to make custom foam inserts and additional options available to meet the needs of your custom case. Read on to learn more.

custom foam inserts

You may be surprised to hear that there are a variety of materials used to make custom foam inserts and additional options available to meet the needs of your custom case.

Custom Foam Inserts: Polystyrene Foam

Expanded polystyrene (think Styrofoam) is a lightweight, rigid, and durable material and a great choice if you need your equipment to stay precisely where you put it when packed. Since it is rigid, there isn’t any wiggle room. This is a closed-cell foam, so any liquid will sit on top rather than being absorbed. Expanded polystyrene is easy to form into completely custom shapes to fit your equipment perfectly.

Polyethylene Foam

Polyethylene is another closed-cell foam, but it offers slightly more flexibility or pliability than polystyrene. Polyethylene foam is very durable and shock-resistant. This makes for a great material for foam inserts that need to support a lot of weight without crushing under pressure. 

Polyurethane Foam

Polyurethane foam is a soft, spongy foam often used for pillows and mattresses. The material is open-cell, meaning it will absorb liquids, and soft, meaning it will deform under pressure. This material is well suited to protect fragile surfaces from scratching. 

Anti-Static Foam

If the material or equipment you transport is susceptible to minor electrical charge or interference, anti-static foam is the best choice for you. This foam is designed to slow electrostatic charge dissipation to protect sensitive equipment such as circuit boards and computer chips. 

Charcoal Foam

Charcoal foam is an excellent choice if the tools or materials you are transporting are used often and sometimes have to be put away dirty. Charcoal foam doesn’t show dirt as much as other foams so it will maintain its professional look longer. If the look of your custom foam inserts is an integral part of your brand, charcoal foam is the way to go.

Convoluted Foam

Just about any of the above options are available in an egg-crate shape, an option known as convoluted foam. This option is named after its form, which looks like the bottom of an egg carton. Eggcrate foam retains the properties of the flexible foam material that it is made from, but it also ensures greater air filtration and flow throughout the case.


PSI Cases have assembled personnel with over 50 years of combined experience in design, engineering, development, manufacturing, and sales. We design and manufacture systems integration packages and container solutions for clientele who represent interest from the private sector and government agencies.No matter what you need to carry, PSI Cases will be sure to have the right case for the job.

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