How to Choose the Right Foam for Your Custom Case Insert


Choosing the right foam for your case insert is critical to ensure your product arrives intact, without scratches, mold, or an overall unpleasant unboxing experience. With the number of foams available, it’s hard to know which one is the “correct” choice. 

Follow these steps to choose the best foam for your custom case insert.

Step 1: Know Your Needs

Before you can choose which type of foam to use, you first need to consider what you need to achieve. Ask yourself the following questions:

Taking these questions with you into the design process will help an experienced packaging expert recommend the ideal foam for your application. 

Step 2: Choose Your Foam

The best way to choose a foam is to work directly with a packaging expert like Foam Industries to select the right material for your project. With so many factors at play, it’s impossible to recommend a one-size-fits-all option.

That being said, there are a few high-level differences between the most common types of foam that you can take into consideration.

► Related Content: What Kind of Foam is Used for Packaging?

Below are the three most common types of foam used in packaging, and their ideal applications.

Polyethylene (PE) Foam

This is one of the most common types of foam you’ll find in packaging. It’s durable, lightweight, easy to fabricate, and resistant to mold and mildew. It can also be fabricated in a way that allows less material to still achieve the same level of quality. These attributes make it ideal for packaging heavier items.

Polyurethane (PU) Foam

Polyurethane foam is ideal for lightweight, fragile, and delicate objects. This flexible foam is easy to fabricate and cut in a variety of shapes, while still offering a high amount of cushioning. 

Cross-Linked Polyethylene (XLPE) Foam

Cross–linked polyethylene is the Cadillac of the foam world. This is the highest-quality protective foam on the market. It’s extremely long-lasting and durable, endlessly customizable, and doesn’t scratch paint. For these reasons, it’s ideal for marketing, branding, and display purposes. 

Step 3: Work with the Right Partner

Picking the right foam for your case insert requires a lot of in-depth knowledge and research. The best way to pick the best option is to work with a partner you can trust to suggest the right foam for your project that hits that sweet spot of necessary durability at the most effective cost.

As a leader in the packaging industry, Foam Industries has set the bar with an unwavering commitment to quality, exceptional client service, and constant innovation. Through our extensive inventory of endlessly customizable products, we ensure you find exactly what you’re looking for.

Contact a Packaging Expert

Foam Industries is a custom protective packaging company specializing in foam – with additional wood and plastic fabrication services. Our custom foam fabrication services are ideal for any type of packaging, display, or support service needed – from design to finished product.

Get a Sample

Sometimes, you need to get a feel for something.
Foam, plastic, and wood samples available on request.