There are various options available when it comes to creating custom made foam inserts for a shipping case or carrying case. Actually, purchasing a pad (solid) is a good way to go if you'd like to cut your own foam inserts. Simply cut the foam tracing your item on the pad using a utility knife. You can also use uncut solid inserts to protect thin items.
Solid pads are available in either Polyethylene or Polyurethane foam. The Polyurethane foam is durable, soft (similar to the foam in the couch cushions) and suitable for both light and medium-weight items. Polyethylene is ideal for both medium and heavy-weight materials because of its density (the foam material is the same as those flotation toys (noodle) that kids play with in the pool).
Eggcrate inserts (or convoluted), work well on their own, which are made of Polyurethane. When the case is closed, the unique grooves in the foam hold them in place grabbing the items.
Another option is to purchase Pick and Pluck, or diced foam. in creating your own inserts, which comes in cubes (pre-scored) of Polyurethane. By placing your items, make your own outline on top of the pre-cut grid. Then you need to remove the cubes making a snug fit for your item.
Foam inserts can be custom made for a perfect fit or added protection. With the perfect use of steel rule dies, die cut foam inserts are made. It produces simply the best product as die cutting actually produces the most precise cut. On the other hand, wire-cut inserts are a good option for deep cases. Using a computer-controlled machine (abrasive wire-cutting), these inserts are created. This is a programmable machine and with the use of Computer Aided Design (CAD) drawing it provides all the details of dimensions and cutouts. And interestingly, both processes allow for either Polyethylene or Polyurethane foam.
You just need not to get panicked if all of these options are literally overwhelming you. Actually, sometimes it’s really hard to decide which insert would be the best fit for your materials. So, if you have questions, it’s a good idea to contact an expert foam insert professional for further guidance. An expert foam insert professional will certainly come in handy.