Foam Packaging

Foam packaging

Foam packaging and cushioning is a great way to protect fragile and valuable items. Foam packaging can be manufactured and fabricated using several different technologies and processes. Combining different technologies allows our customers to utilize the endless solutions foam has to offer. There are also many different types of foam with unique properties and densities to consider depending on the application. With all of these options available, you need a trusted packaging partner to help make sure you make the smartest decisions for your packaging.

Foam Packaging Design

Foam packaging is often combined with other packaging items such as corrugated, rigid boxes, or cases to create truly remarkable packaging. For example, the item pictured below is water jet cut blue crosslink foam inside of a hinged magnetic binder box.
View 2 Blue Rigid Setup Box from PAX Solutions
PAX Solutions designed the foam so that all items were flush with the top of the foam, which is important for protection and aesthetics. This involved cutting multiple foam plugs and layers of foam so that all the items of varying sizes would sit at the same height. Hand holes were cut into the sides of the top foam layer to easily access the components held by the bottom foam layer. The end result was a protective package that also conveyed the engineering, quality, and value of the medical device inside.

Foam Manufacturing


PAX Solutions offers industry leading foam manufacturing and fabrication capabilities backed by years of experience and technology advancement. With the capabilities listed below, PAX Solutions is positioned to be your reliable foam partner.

Don’t settle for die cutting when you need water jet cutting!

· Precision water jet cutting

· High speed die cutting

· Vertical and horizontal contour cutting

· Abrasive wire cutting

· Convoluting (eggcrate)

· CNC Routing

· CNC pattern cutting

· Vacuum and roll skiving

· Heated plank lamination

· Numerous foam lamination methods for assemblies

Foam Packaging Materials

There are many different types of foam packaging materials that specialize in different aspects of packaging. Features of different foams include shock absorption, scratch/friction reduction, adhesive backing, anti-static, void fill, aesthetic value, and many others. Here are some of the more common foam materials used for foam packaging.

Polyurethane is a spongy open cell foam.
PU is ideal for products that require shock absorption and cushioning.

The surface of PU foam is nonabrasive and safe for contact with most surfaces.

PU foam comes in different densities which are used depending on the weight and size of the product being packaged.

Common colors are white or various shades of grey.

PU Polyurethane Foam from PAX Solutions

Polyethylene is a sturdy, resilient closed cell foam.

PE foam is ideal for products that require shock absorption, insulation, and vibration dampening.

The surface of PE foam is textured, so items that can scratch easily should not be packaged in direct contact of PE foam.

PE foam comes in different densities depending on the weight and size of the product being packaged.

Common colors are white or black.

PE Polyethylene Foam from PAX Solutions

Convoluted foam, also know as eggcrate foam, refers to the shape of the foam.

It can be manufactured using most foam materials, but PU and PE are the most common.

The peak-and-valley eggcrate appearance provides more cushion than other types of foam packaging and allows for increased air flow.

The shape helps the foam fill more internal space using less total material.

Convoluted Foam

Expanded Polyethylene is closed cell beaded foam.

This foam is lightweight and performs the same, if not better, than standard PE foams.

Customers can use less foam material and still achieve great protection.

EPE offers protection for Class A surfaces meaning delicate surfaces, such as powder coated metals, will not scratch when in contact with EPE foam.

Common colors are white or black.

EPE Foam

Crosslink foam is a high-end closed cell foam.

It is one of the more expensive foam options, but also very popular because it offers great protection and presentation.

Crosslink foam offers protection for Class A surfaces meaning delicate surfaces, such as powder coated metal, will not scratch when in contact with crosslink foam.

XLPE foam is very dense with a smooth, cleaning looking appearance.

Crosslink foam is commonly used in the medical industry because it is ozone resistant. XLPE foam comes in many different colors.

Crosslink Foam Colors

ESD Foam is comprised of three sub-categories: Conductive Foam, Static Dissipative Foam, and Anti-Static Foam. There are closed and open cell foam options available for all three categories.

The specific ESD properties of the product being packaged will determine which foam should be used for which applications.

Most anti-static foam is pink; however, all three sub-categories are available in various colors.

ESD Foam

Learn More About Our Foam Solutions For Your Business

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