What should you know before choosing foam?
Start with four facts about the product: its weight, its outer dimensions, how sensitive its surface is and how it travels (parcel, pallet or returnable container). A 200 g electronic module and a 20 kg machined part need very different foams, even if they are the same size. Write these values down before you request a quote; they decide almost every later choice.
Which foam type fits which product?
Polyethylene (PE) foam is the standard choice for industrial parts: it is closed-cell, light, moisture resistant and absorbs repeated impacts. Polyurethane (PU) foam is softer and open-cell, so it suits light, delicate or high-gloss items such as instruments and cosmetics. Cross-linked polyethylene (XLPE) has a finer cell structure and a cleaner cut edge for visible, premium inserts. EVA and EPDM are used where elasticity, sealing or weather resistance matter.
How do density and thickness affect protection?
Density, measured in kg/m³, controls how much load the foam carries before it compresses. Heavy parts need a higher density so they do not sink to the bottom of the cavity; light, fragile parts need a lower density so the foam can cushion the shock. Thickness gives the foam room to decelerate the product: as a rule, leave a foam wall on every side of the part rather than letting it touch the box.
Which cutting method should you use?
CNC and water-jet cutting produce exact cavities from a CAD drawing and are best for complex shapes and repeat orders. Die cutting is the most economical method for high volumes of flat parts. Lamination joins several layers so deeper or multi-level cavities can be built. FoamPackage checks each new design with a sample insert before series production.
What is the most common mistake?
The most common mistake is choosing foam by price per sheet instead of by the product it protects. A cheaper, softer foam that lets a heavy part bottom out during transport costs more in damaged goods than it saves. Ask for a sample and test it with your real product and real shipping route.