Your valuable products deserve more than just a case. They deserve engineered protection that travels with them.
At Polyformes, our bespoke case foam inserts are custom-cut to your equipment, offering optimal shock absorption, component retention and presentation quality.
Whether for field engineers, sales demo kits, electronics, medical devices or delicate instruments, a well-designed foam insert can be the difference between safe arrival and costly damage.
You can even take it one step further and turn it into a sales tool by branding the inserts with 4 colour print or laser etching.
Poorly supported items shift under transport forces. A snug-fit insert guarantees each component sits exactly in place, eliminating vibration, collision and abrasion.
Case foam inserts provide high protection, are custom-fit to minimise movement and prevent transit damage.
Not all foam is the same. By selecting the correct density, thickness and grade, a foam insert can cushion against drops and vibration. This is how you prevent breakage and maintain calibration. Using CAD / design software to calculate the optimum foam density and grade for your items.
High-value items often have polished, coated or delicate surfaces. Foam inserts offer a soft, conforming barrier that resists scratching, marring or staining under repetitive contact. A no-brainer when it comes to enhancing your protective cases.
Beyond protection, foam inserts can be a sales tool. Options include:
Layering foam colours or laminating for better presentation and tool control effects.
A clean, pre-cut insert speeds up packing, makes missing items obvious at a glance, and dramatically reduces returns from damaged goods. It's both an operational and brand win.
We work with a range of advanced foams, each selected for its protective, handling or aesthetic properties.
| Foam Type | Ideal Use Cases | Key Strengths |
|---|---|---|
| Plastazote® (cross-linked PE foam) | Sensitive equipment, electronics, aerospace | Excellent shock absorption, chemical inertness, moisture resistance, wide colour range |
| Standard PE / Ethafoam | General or high-volume inserts | Cost-effective, reliable protection in many transit uses |
| ARPLANK / Recycled Foams | Sustainable packaging lines | Reduced environmental impact, designed for recycling |
We combine CNC routing, laser cutting, lamination and foam layering to deliver the final insert exactly to your specifications.
Case foam inserts will be designed and manufactured to follow every contour of your items. Specialist software can calculate the required density for the optimum level of protection.
Throughout, we guide you in choosing optimal foam grade, density, and protective layering based on your application.
No matter your industry, well-engineered foam adds peace of mind, reduces logistic losses and improves the perceived value of your kit.
Pick-and-pluck foam is pre-scored and allows generic cubing; it's flexible but less precise. Custom inserts are designed to your product contours, offering superior retention and protection.
Absolutely. We design inserts to work with waterproof, aluminium, plastic, and flight cases. We can even source the case for you to ensure compatibility.
We stock a wide palette of colours in most foam grades. You can layer colours or choose contrast inserts for tool control or branding.
Yes - for electronics or sensitive equipment, we supply specialist static-dissipative or conductive foam grades.
From design approval to delivery typically takes 7 to 21 working days, depending on quantity and complexity.
Ready to protect your investment?
(or upload your drawings) and let's design your ideal case insert.
