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.
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.
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.
OUR PRODUCTS
No matter the size or sensitivity of your product, Vol Case has a protective packaging shipping solution for you.
Wood Crates
All of our crates are stamped and certified for international export. Whether you need a single small crate delivered to you or dozens of oversized crates built onsite at your facility, we can handle the job. Our crates are fully customizable and can include foam, shelves, shock absorbers, ramps, latches, and more. We have experience building both commercial and military crates for equipment weighing 70,000+ lbs. Learn more here.
ATA / Road Cases
ATA / Road cases are best for highly sensitive objects that are light enough for one or two people to lift and move around. Our ATA cases can be either wood or plastic siding and all have durable metal edging. All ATA cases come with custom foam interiors and can have any number of wheels, handles, partitions, straps, latches, and more. Our cases are split or pop riveted together to ensure maximum strength and durability. Learn more here
PE & Wood Containers
If you need something lighter or cheaper than an ATA case, our PE and wood containers are the solution. PE containers are made with a strong, but lightweight, plastic siding and no metal edges. This provides a lighter and cheaper option to an ATA case, while still very durable. Our wood containers are made with wood sides and metal edges and are our most cost effective case option, but are heavier than the PE version. Learn more here.
Trunk Cases
Trunk cases are perfect for equipment regularly transported by box truck. Our trunk cases come in three sizes: Small - 22.5” x 30” x 30”, Medium - 22.5” x 45” x 30”, & Large 30” x 45” x 30”. These exterior dimensions allow them all to fit neatly in a box truck for maximum capacity. All trunk cases include handles, latches, four swivel castors, and castor cups on top to allow for secure stacking. As needed, labels, dividers, and foam can be added as well. Learn more here.
Injection Molded Cases
We are a certified distributor for Pelican, SKB, and Nanuk cases, meaning we offer better pricing than you’ll find anywhere else. All of our injection molded cases are watertight, comply with military specs, and are built to withstand the harshest environments. Custom waterjet or CNC cut foam inserts are available for all cases for maximum protection. Whether you need a case to hold one object or many, we can design a case for you. Learn more here.
Waterjet & CNC Cut Foam
We offer a wide range of foam types, densities, and colors to best fit your needs. We offer foams types such as PE, PU, Crosslink, and Zote foam. All of these are available in a variety of densities depending on the weight and sensitivity of your equipment. We also offer colors other than the standard black/charcoal and have options such as anti-static. All these foam varieties can be waterjet or CNC cut to perfectly fit your product. Learn more here.
CONTACT US
Whether you need one wood crate or hundreds of ATA cases, we’d love the chance to earn your business. All of our designs and quotes are done for free without any purchase required. We are able to work off dimensions/CAD files that you provide to us or we can visit your facility to take measurements of the equipment.
(865) 481-3801
sales@volcase.com
328 Warehouse Rd. Oak Ridge, TN 37830