In conclusion, custom foam inserts are an essential component of packaging and shipping products. The type of foam you choose will depend on your specific needs and budget. Essentially, if you are looking for the best shock absorption, PU is ideal. If you are looking for the cheapest foam, PE is the best. And if you are looking for the most visually appealing foam, crosslink is what you want. While there are other considerations such as, water-resistance and manufacturability, those three factors will cover most use cases. If you have a niche situation though, please reach out to us. We’d be happy to help.
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Custom Foam Inserts: PU, PE & Crosslink Foam
Custom foam inserts are an essential component of packaging and shipping products, as they provide a high level of protection and cushioning for the contents. When it comes to custom foam inserts, there are several different types of foam to choose from, including PU, PE, and crosslink foam. Each type of foam has its own unique properties and characteristics, and the best choice for you will depend on your specific needs and budget.
What is PU foam?
PU foam, also known as polyurethane foam, is a versatile and durable foam that is often used in custom foam inserts. It is known for its excellent shock absorption and cushioning properties, making it an ideal choice for protecting fragile items during transport and storage. It is also unlikely to scratch the surface of anything you put in it, making it a great choice for equipment with senstive lenses or detectors. Additionally, PU foam is easy to cut and shape, making it a versatile material for custom foam inserts.
What is PE foam?
PE foam, also known as polyethylene foam, is another popular choice for custom foam inserts. PE foam is a closed-cell foam, which means that it is resistant to water and chemicals. Other foams, like PU, are open-cell foam, meaning that liquids and air can travel through the foam. This difference makes PE foam a great choice for items that need to be shipped or stored in damp or humid environments. Additionally, PE foam can be cut in a variety of ways including with the use of a CNC router. This allows you to cut and shape a complicated design with multiple layers, out of one piece of foam. PU foam on the other hand, needs to be cut in multiple layers for each depth level of the foam and then glued together. The ability to be cut out of a single piece of foam, allows PE foam to remain strong and not have glue points that could come apart during shipping.
What is crosslink foam?
Crosslink foam, or EVA foam (which is a very common variant), is a popular choice for custom foam inserts. It has many of the same benefits of PE foam such as being a closed-cell foam so it is much more water resistant and can be cut using a CNC router. The main reason that customers choose crosslink over PE, is because they like the look and finish of it. PE foam is more of a utility foam, whereas crosslink is a lot more aesthetically pleasing. If branding or impressing your customer when they see the equipment and foam is important to you, crosslink may be the better choice.
No matter which foam type is best for you, they all come in multiple density and color options. They are all able to be precision cut as well. In terms of price, on average, crosslink is the most expensive, followed by PU, and then PE. This can sometimes change depending on the size of the foam set vs. the size of the raw material, but that order will almost always hold true.
About Vol Case
Volunteer Case & Container is the oldest custom crate and case manufacturer in the East TN area. Founded over 30 years ago, all of our protective packaging solutions are still designed and assembled at our facility in Oak Ridge, TN. We specialize in custom wood crates, ATA cases, wood or plastic containers, injection molded cases, and waterjet or CNC cut foam inserts. Our customers span a variety of industries including nuclear, government, aerospace, military, medical, R&D, and more. Our team has experience designing and building everything from huge wood crating for 70,000+ lbs machinery to small injection molded cases for key-sized objects. Whatever your needs, our team works on quick turnaround times to provide you with high quality protective packaging. Contact us today for a free quote.