Foam is tough, but lamination makes it tougher — and better looking. By adding an extra layer, lamination reinforces foam’s natural strength while opening the door to more design possibilities. The result? Packaging that doesn’t just protect your product but also makes a statement when customers unbox it.
At Foam Industries, we’ve seen how lamination can turn standard inserts into high-performing, brand-elevating packaging. In this guide, we’ll break down what foam lamination is, how it works, and why it’s the simplest way to boost both durability and design.
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First, you need to understand what lamination is. Foam lamination is the act of layering composite material to change the appearance of a piece of foam. This can be done with other types of foam, other textiles or coatings. For foam packaging, this is used as the final step to change the appearance of a piece of foam, typically a case insert.
There are two primary ways foam is laminated: through adhesive lamination and heat lamination.
Adhesive lamination is exactly what it sounds like. It’s when an adhesive is applied to the surface of your foam part to laminate it. This can be done through pressure-sensitive adhesives or heat.
Heat lamination bonds two foams together using an elevated temperature that melts the components. In this process, two foams are put through a machine together and fused using heat. The melting foam forms a glue that fuses the two surfaces into one.
Here are some of the benefits that you can gain from using laminated foam for packaging:
Foam lamination has numerous advantages in the packaging industry. Whether it’s for practical or aesthetic purposes, foam lamination can provide added benefits for a better project result every time.
Now onto the part that most people care about: why would you laminate foam? Typically, it’s for one of two reasons (or both): to make it perform better or look better.
So two words: performance and pizzazz.
On its own, foam is already pretty strong, but it’s still susceptible to breakage with the right impact. Lamination offers an extra layer of protection to keep the inner foam from being damaged while also offering a more presentable exterior. Lamination makes foam tougher, more moisture-resistant, and less likely to get banged up.
Because foam lamination allows you to combine multiple materials together, you can tap into the advantages of those other materials. For example, you might laminate a piece of foam to help improve its ability to repel moisture. This can be useful to further protect the item itself and retain the design of your piece of foam. The better you’re able to protect your products, the more likely they are to arrive in your customers’ hands on time and undamaged.
But it’s not just about performance. Applying a laminated finish to your foam insert opens up a new world of design possibilities. The smooth surface of laminated foam makes it easier to add text, logos, and imagery. Paired with a bold color, that’s why it’s a popular choice for influencer kits.
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Let’s look at one example, from a project we worked on with a client.
Here, laminate is used on the case insert to create a backdrop in the iconic Coke red. This not only elevates the entire appearance of the packaging, but it also helps subtly reinforce the brand’s identity.
Together, performance + pizzazz = happier customers, better reviews, and fewer “oops, it broke in the box” moments.
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Foam lamination offers strength and beauty in your packaging, but it also enhances customer service. Furthermore, the glossy, smooth appearance adds an extra wow factor that leaves a lasting impression on consumers. Overall, foam lamination can improve customer satisfaction, leading to more positive reviews and more business.
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.
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.