Custom Foam Inserts

Sep 16, 2017

At KinFish Case, we have spent the last 10 years designing EVA cases and foam insert, so we know how to make custom EVA cases that safely cradle everything from sensitive electronic equipment to rugged tools. Part of the secret is the foam we use to customize the interior of many of our EVA cases. Custom foam insert greatly enhances your product’s appeal and adds product longevity for the end user.

We offer several options for foam material, including EVA foam, sponge foam and EPE foam. We also have a wide selection of foam colors, grades and thickness, to protect well and display your products.

Based on your products, cases, applications and anticipated external wear, we can provide the best protection solutions for your custom foam insert.

EVA Foam
EVA foam is popular choice for custom foam insert. EVA Foam is a firm closed-cell foam with a softer, more rubbery feel than our polyethylene (cross-poly) offering. Its surface squishes down when you press your fingers into it, quickly bouncing right back into place. Stock colors are white and dark gray but other colors are available. (Minimum order quantities 5000 pcs)

Available manufacturing process:
- Die cutting
- Thermoforming
- Laser cutting

- CNC routing

Sponge Foam
Sponge Foam is the most familiar material for customized insert. Its features are crispy and light. Color charcoal gray.

Available manufacturing process:
- Die cutting

Convoluted Foam
Convoluted foam is sometimes called “egg crate foam”. It is a versatile polyurethane foam used commonly as lid foam in injection molded cases.

Available manufacturing process:
- Die cutting

EPE (Expanded Polyethylene) Foam
EPE foam is a closed cell beaded polyethylene which has a low weight, high strength ratio. It is a semi-rigid, non-cross-linked and closed-cell type of polyethylene foam. Cellu-Cushion-6.0 pound PE. This 6 pound polyethylene foam is generally added as a thin top layer to custom foam cushions to add color and strength to the cushion. We can also use this foam to put colored logos in foam cushions. Stock colors are white and black but other colors are available. (Minimum order quantities 5000 pcs)

Available manufacturing process:
- Die cutting
- Laser cutting

Depending on the application, quantity and complexity of your products, we can use one of several different manufacturing process to deliver an customized EVA case interior.

Die-cutting is one of most familiar way for various foam insert. With die-cut tooling and punch press, a foam would get cut to the shape of your equipment. Die-cut foam insert can be very cost-effective at larger quantities, and we operate a wide range of die presses to give our customers a full range of customization options.

Thermoforming is one of most familiar manufacturing process for EVA foam. It works the same as EVA thermoformed insert, the dent can be any shape (such as arch shape) to be perfect fit for your products. Thermoformed EVA insert can be very cost-effective at larger quantities, and can laminate surface material you prefer.

Laser Cutting
Laser cutting is mainly used for thicker EVA foam which it cannot be die-cut. With laser cutting process, the sides of opening would get nicer than die-cut foam. The drawback is lower production efficiency and higher costs.

CNC Routing
CNC Routing is a great option for complicated EVA foam insert with different depth dent. CNC foam routing machines use high speed rotary cutters to remove foam material and deliver precise, accurate custom EVA foam interiors. Taking input directly from a CAD program, CNC routed foam is an excellent option for making one-off cases, or developing initial prototypes for a larger run. The drawback of this process is the price, which is more expensive than above.

Get a quote on your project now and find out why more people choose KinFish Case every day for all their EVA case and foam needs.

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