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 foams 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

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. 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 is extremely versatile and can be cut or molded into virtually any shape or size.

If you can dream it, PAX can design it.

Our design services include:

  • 3D scanning

  • Solid Works design service

  • CNC programming

  • Product Design Consultations

  • Sampling and first articles

  • Package testing and analytics

Blue Rigid Setup Box from PAX SolutionsView 2 Blue Rigid Setup Box from PAX Solutions

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!

Capabilities include:

· 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. Below are some of the more common foam materials used for foam packaging.

Packaging for every product.

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Polyurethane (PU)

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.

Polyurethane Packaging

Polyethylene (PE)

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.

Polyethylene Packaging

Convoluted (Eggcrate)

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 Eggcrate Packaging

Expanded Polyethylene (EPE)

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.

Expanded Polyethylene Packaging

Crosslink Foam (XLPE)

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 Packaging

ESD Foam (Anti-Static)

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 Anti Static Foam Packaging
Industries that commonly use foam: analytical instruments, aquaculture, artwork, audio/video equipment, cabinets, computer hardware, custom packaging, dental equipment, dental supplies, displays, electrical components, electronics, firearms, flowers & plants, frames, food products, furniture, gift baskets, glassware, industrial equipment, industrial supplies, lighting, medical devices, medical equipment, medical supplies, music instruments, optical equipment, optical supplies, pharmaceuticals, precision tools, prosthetics, refrigerated items, replacement parts, safety equipment, servers, windows, wine.

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