Protective Packaging and Custom Foam Inserts

Versatile and practical

Custom foam inserts and protective packaging products offer high cushioning and compression strength to protect fragile products throughout manufacturing, shipping, and final delivery.

Our Packaging Advisors help you develop custom packaging solutions that protect your product and deliver a great end-user experience — because safely packaged products translate to happy customers.

The Benefits of

Custom Foam Inserts

Custom foam inserts and packaging components can significantly enhance your package’s ability to protect your product from damage. With our custom foam fabrication, we convert raw materials into protective packaging solutions tailored to your product’s specific shape and needs. 

Foam converting methods offered by The BoxMaker include die-cutting, heat welding, gluing, and CAD cutting. We can also source molded foam products and provide instant solutions, including foam-in-place.

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Custom Fabricated Foam Materials

Our Foam Fabrication division uses a wide variety of open- and closed-cell foams to design and fabricate product-specific interior protection, including:

  • Polyethylene (PE)
  • Polyurethane (PU)
  • Molded Expanded Polystyrene (EPS)
  • Foam-In-Place (FIP)
  • Expanded Polyethylene (EPE)
  • Expanded Polypropylene (EPP)
  • Specialty Foams (Crosslinks, EVAs, IV foams, conductive foam, blends)
  • Cold Chain Packaging: Thermal Sensitive Design, Polystyrene molded coolers, 6-piece Liner Sets in Styrene or Green Cell Foam®

Foam Converting Solutions

The BoxMaker can design and fabricate a range of product-specific foam converting solutions to reduce shipping damage, including:

  • Pads
  • End caps, hinged end caps, corner caps
  • Case inserts (custom foam inserts)
  • 6-piece liner sets
  • Edge and corner profiles
  • Abrasion protection
  • Void fill
  • Structural and weight protection.

Our structural design team will help you identify the best product for:

  • Protection
  • Aesthetic appeal
  • Anti-static or conductive needs
  • Thermal sensitivity
  • Blocking and bracing
  • Sustainability
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Protective Packaging Foam Alternatives

We supply many choices for blocking and bracing to protect your products and reduce shipping damage, including:

  • PAD LOC® Pads
  • Bubble wrapping
  • Suspension and retention packaging
  • Custom corrugated inserts
  • Honeycomb
Sustainable

Foam and Foam Alternatives

Foam is a reusable packaging material. All of The BoxMaker’s foam material waste ends up right back in the supply stream to be recycled or reground and reused.

Our polyethylene (PE) foam materials contain a minimum of 65% recycled content. For brands highly motivated to employ eco-friendly foam products, biodegradable foam materials made from corn can be sourced when purchased in large quantities.

We are committed to offering sustainable packaging material choices whenever possible.

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Let’s Talk

Protect Your Products and Customer Satisfaction

Our Packaging Advisors help you develop custom packaging solutions that protect your product and deliver a great end-user experience — because safely packaged products translate to happy customers.