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Foam Case Inserts Available
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Foam Case Inserts

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Supplying reusable, as well as disposable, custom foam case inserts for over 25 years has presented New England Foam the knowledge & experience to provide clients with the most reliable & affordable custom foam cases available in the entire foam fabrication industry.

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Commercial Foam Case Inserts


New England Foam’s custom foam case inserts are utilized in commercial & industrial applications for presentation packaging & also in protective packaging; to organize the contents of the case while providing protection from shocks & drops.

New England Foam’s custom foam case inserts for packaging provide the absolute best in organization, protection & security for the interior of your case without sacrificing aesthetics.

New England Foam’s custom foam case inserts are available in a variety of colors, densities & product grades.

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Types of Foam Case Inserts Available

New England Foam fabricates custom designed case inserts including open-cell foam case inserts comprised of polyurethane foam (polyester & polyether) & closed-cell foam case inserts comprised of polyethylene foam (crosslinked & expanded).

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Polyethylene Foam Case Inserts


Polyethylene foam case inserts provide superior protection & unparalleled durability for the interior of your case.

Polyethylene foam is a lightweight material that is inherently non-abrasive, non-dusting & easy to fabricate.

Polyethylene foam case inserts demonstrate superior shock absorption & vibration dampening properties & are impervious to bacteria, mildew & mold.

Polyethylene foam case inserts have a high load bearing capacity, which helps end users reduce costs due to using less material without sacrificing protection.

Great insulation properties along with a high-resistance to chemicals & solvents make polyethylene foam the ideal choice for packaging heavier items & for materials handling (dunnage) applications.

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Crosslinked Polyethylene Foam Case Inserts

Crosslinked polyethylene foam, also known as PEX or XLPE, is a flexible, closed-cell type of foam that is widely revered as the most luxurious material in the packaging industry today.

Best-known for its ability to protect class A surfaces, crosslinked polyethylene foam can be fabricated into durable & aesthetically pleasing custom foam case inserts for the packaging industry.

When appearance is the main objective, in presentation packaging for example, then crosslinked polyethylene foam case inserts are the only choice.

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Polyurethane Foam Case Inserts


Polyurethane foam, also known as PU, PUF or PUR, is a flexible, open-cell type of foam.

Polyurethane foam case inserts provide the best value for lightweight, delicate objects with high-fragility.

Polyurethane foam case inserts are widely used in the medical packaging industry as well as other applications where abrasion resistance is essential.

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Pick-n-Pluck Foam Case Inserts

Pick-n-pluck, also known as diced, perforated & pinch & tear, is a component foam case insert system that is typically comprised of three layers of foam.

The first layer of conventional polyurethane foam is to be used as the base, or pad, for the contents of the case.

The second layer of polyurethane foam is pre-scored into tiny cubes that will inevitably be customized by each end-user; hence the term, “pick-n-pluck.”

The third layer of polyurethane foam is convoluted, or egg-crated, & is utilized as a gripper, or lid, to hold the contents of the case in place.

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Fabricating Foam Case Inserts


New England Foam’s custom case inserts for the packaging industry can be fabricated as one composite piece of foam for durability or multiple component pieces for accessibility.

New England Foam’s custom foam case inserts can be custom designed to create multiple cavity depths ensuring the perfect fit for all of your individual components.

Foam case inserts can be CNC (computer numerically-controlled) routed or die-cut; both methods provide an affordable means of fabrication for short, low-volume runs as well as long, high-volume runs.

Previously fabricated foam case inserts include: custom tool trays, display packaging, electronic/delicate equipment packaging, transportable test equipment, storage, shipping & personal selling (sales) sample kits. 

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Flocked Foam Case Inserts

New England Foam also has the capability to enhance the appearance of each foam case insert with the addition of foam flocking.

Flocked foam is easily laminated to polyurethane foam, polyethylene foam, chipboard, corrugated & plastics.

New England Foam fabricates foam flocking in standard size rolls of 1/8" x 27" x 300' (100 yards).

Custom colors & 54" wide rolls are available upon request.

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