Packaging Fabrication and Production Capabilities

Foam Industries builds protective packaging that performs in real-world conditions. Every project starts with the product, the environment it moves through, and the performance requirements that keep it safe. Foam is at the core of what we do, with supporting materials like corrugated, plastics, custom wood components, and sewn parts added when a hybrid solution delivers better protection or usability. Whatever the scope, the goal is always the same: protection you can trust and repeatable results you can measure.

Engineered Packaging That Starts With Your Specs

A strong design starts with clear requirements. You bring the drawings and performance targets. We translate those into a reliable solution.

Our engineering team reviews your CAD files, tolerances, and intended shipping conditions. We look at impact limits, drop heights, cushioning needs, and any constraints from fixtures or assembly workflows. This process eliminates guesswork and prevents over-engineering so the final design protects your product without adding unnecessary weight or cost.

Material Expertise for Complex Applications

Material selection drives cost, weight, and performance. We help you choose the right materials for your specific application. While Foam is in the name, it's not all we do. Our engineers and design team work with you to determine the most cost-effective options that will deliver on performance.

Materials We Use

Precision Fabrication Capabilities

The final product is only as good as the manufacturing process. Our equipment is tuned for accuracy and consistency across thick, thin, complex, or high-volume parts.

CNC Routing

Waterjet Cutting

Flash Cutting

Die Cutting

Vertical and Horizontal Contour Cutting

Skiving and Roller Burnishing

Hot Plate Laminating

PSA Laminating

Foam Convoluting

Testing, Validation, and Performance

Reliable protection comes from data, not assumptions. We validate designs through prototyping and real-world testing so performance is documented before production begins.

Drop testing to confirm G-force limits.
Cushioning curves to show how the foam behaves under load.
Compression and deflection measurements for fit-critical parts.

Move forward with the confidence that the packaging will protect the product under the stresses of shipping, storage, and handling.

Want the deets? Explore Technical Documents

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Why Choose Foam Industries?

We focus on stable lead times, predictable costs, and repeatable results across every run. And, we like to have a bit of fun while we're at it.

Data-backed production with quality checks.
Reliable sourcing for all materials.
Quick-turn prototypes or large-volume runs: scale at your pace.
A commitment to sustainable manufacturing.
A creative team that aren't afraid to problem solve.
Proactive communication, and one main point of contact for each project.

Integrated Packaging Solutions

Many projects need more than a simple foam insert. We build full systems using foam, corrugated, plastics, custom wood components, and sewn assemblies when the design calls for it. These hybrid builds keep everything working together as one unit and arrive ready for your team to use.

This approach streamlines your supply chain and keeps design, engineering, and assembly under one roof.

Explore Past Projects

Start Your Project

If you’re an engineer, send your CAD file and performance requirements. We’ll review geometry, materials, and protective targets and recommend the best path forward.

If you’re comparing vendors or reviewing budgets, we can quote material options, lead-time ranges, and production pathways.

Your product deserves packaging that’s engineered, tested, and built to last through every mile. Let's get started!

Frequently Asked Questions

Do you build full packaging systems or only foam?

Foam is our specialty, but we also build hybrid systems that use corrugated, plastics, custom wood components, and sewn parts when the design calls for it. On occasion, completed projects don't involve foam at all. If your goal is to get something from A to B without damage, to provide a bespoke kit, or optimize transportation, reach out to us!

How early should we involve your engineering team?

As early as possible. A quick review of your CAD file, tolerances, and shipping conditions helps avoid redesigns later. Early collaboration also prevents over-engineering and keeps costs controlled.

Can you work from existing packaging designs?

Absolutely. We can replicate, adjust, or fully re-engineer an existing design. Many clients come to us looking to reduce cost, improve protection, or streamline assembly.

What files do you accept?

We work with most standard formats including STEP, IGES, DWG, DXF, and native SolidWorks files. If you’re unsure, send what you have and we’ll take it from there.

I have a product but I need a design for a package. Will you create something for me?

Our strength is working with your design teams to create something even better. We do review existing designs for manufacturability, cost-effectiveness, and performance. We typically do not provide full-scale design and engineering services for brand new products. However: our team also doesn't shy away from a challenge. If you are looking for more heavy-duty design support, please still reach out. While it's not a core service, it is something we have provided on a case-by-case basis.

How fast can you produce prototypes?

Most prototypes can be turned quickly once we understand your design targets. Timing depends on material availability and complexity, but rapid iterations are a core service.

Can you support high-volume runs?

Absolutely. We can handle small to large runs. Lead times remain predictable as volume grows.

Do you sell raw materials?

We do not. We source a wide range of closed-cell and open-cell foams, primarily from our partner Pregis.

What are your sustainability initiatives?

We support sustainable manufacturing and supply chain logistics by smart material selection, post-production recycling, and consumer education. You can dive into our sustainability initiatives on our Sustainability Packaging page.

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