Polyurethane (PU) Foam Packaging Solutions

When making a good first impression is critical, Polyurethane Foam is the perfect choice. With added protectivity against vibration, polyurethane is a great choice for anything from influencer kits to aerospace applications.

When products are sensitive, irregular, or prone to shock or vibration-related damage, polyurethane foam is often the right fit.

Want to see it for yourself?

Get a Quote

Why Polyurethane Foam Works for Protective Packaging

Polyurethane foam is valued in packaging applications for how it cushions and recovers under impact. These characteristics make polyurethane foam a strong option for packaging products that need protection without excessive rigidity.

usda logo

Benefits of Polyurethane Foam

Soft and plush for hands-on touching
Sustainable - all post-industrial waste is recycled and product can be recycled after use
Provides cushioning for sensitive and fragile projects
Offers vibration control during long or multi-leg shipments
Excellent for applications where softer energy absorption reduces damage risk

Common Applications

Custom case inserts within corrugated or wooden boxes
Vibration control for fragile products
Packaging for sensitive products with complex shapes
Protective inserts where controlled compression matters

Industries Served

Industries

Industrial

Medical

Automotive

Aerospace & Military

simplified icon of three interconnected loudspeakers

Branding & Marketing

Fixtures & Displays

Check out the many applications of Polyethylene Foam with some of our past projects.

View the Full Gallery

Why Choose Foam Industries for Polyurethane Foam Packaging?

Choosing the right foam is only part of the equation. How it’s designed and executed matters just as much. We solve packaging problems.

At 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.

Meet the Team

Frequently Asked Questions

Is polyurethane foam good for protective packaging?

Yes. Polyurethane foam is commonly used in protective packaging when shock absorption and vibration control are priorities. It provides softer cushioning than more rigid foams.

How is polyurethane foam different from polyethylene foam?

Polyurethane foam generally offers softer cushioning and better vibration absorption, while polyethylene foam provides more rigid support and durability. The right choice depends on the product and shipping risks.

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.

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.

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. Other suppliers include:

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.

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!

View All