We design and manufacture custom foam inserts in EPE, EVA, PU and cross-linked PE, die-cut for volume runs and CNC-routed for deep or complex cavities. Work starts from your DXF, a 3D scan, or the physical part sent to our Rajkot plant.
A foam insert holds the product instead of merely surrounding it. That single difference — a cavity the part sits into rather than a blanket wrapped around it — is what turns a pack that survives handling into one that survives a drop.
We fabricate inserts from the four foam families that matter in packaging, choosing between them on the product rather than on what we happen to stock. Most jobs start with a sample part and end with a prototype in your hands inside a week.
Supply specification
| Fabrication | Die-cutting, CNC routing, waterjet, contour and convoluted cutting |
|---|---|
| Materials | EPE, EVA (60–120 kg/m³), PU (16–40 kg/m³), cross-linked PE |
| Input accepted | DXF / DWG, STEP, 3D scan, or the physical part |
| Prototype lead time | Typically 3–7 days from approved drawing |
| Tooling | Die cost for die-cut runs; none for CNC |
| Choose die-cut when | Volume is high and depth is under ~10 mm |
| Choose CNC when | Depth, undercuts or low volume make a die uneconomic |
Die-cut or CNC — the decision that sets your cost
Die-cutting presses a shaped steel rule through the foam. It is fast and cheap per part, but the die costs money upfront and cannot hold a clean wall much beyond 10 mm of depth. It is the right answer for high volumes of shallow cavities.
CNC routing cuts the cavity with a spindle following a toolpath. There is no tooling cost and no depth limit, so it suits deep cavities, undercuts, low volumes and anything still changing. Per-part cost is higher, which is why volume eventually moves a job to a die.
For most customers the honest answer at first order is CNC — it avoids committing to a die before the design has been proven on a real transit route.
How we specify the foam, not just the shape
Getting the cavity right is only half the job. The material has to match the failure mode: EVA where the cavity is visible and must hold tolerance, PU where the geometry is complex or the finish is delicate, EPE where the priority is cheap impact absorption, cross-linked PE where appearance and fine cell structure matter.
Density then follows from load. A cavity wall that slumps under the product is not protecting it — for tool trays and repeatedly opened cases that means 100–120 kg/m³ EVA rather than the 60–80 that would be adequate for a one-way pack.
Industries we supply
Medical devices & diagnostics
Precision EVA cavities for instruments, probes and reusable carry cases.
Electronics & instrumentation
Anti-static and conductive fitments for boards, meters and calibrated equipment.
Tool control & shadow foam
Two-tone CNC trays at 100–120 kg/m³ where a missing tool must be visible instantly.
Automotive & engineering
Multi-cavity trays for returnable bins and partitioned layers for machined components.
Dispatch & lead times
| Prototype | 3–7 days from approved drawing |
|---|---|
| Production (die-cut) | 7–14 days after die approval |
| Production (CNC) | 5–10 days, no tooling wait |
| Repeat orders | 3–5 days against a held drawing |
Common specifications
Common questions
Are you a foam inserts manufacturer for small runs, and do you make custom foam trays?
Yes. As a foam inserts manufacturer we run CNC routing for prototypes and small runs with no tooling, and die cut foam inserts for volume runs where a steel-rule die pays back. Custom foam trays, multi-cavity layer pads and shadow-foam tool trays are made in EPE, EVA and PU from a drawing, a STEP file or the physical part.
How do I get a custom foam insert made?
Send us the product — a DXF, a STEP file, a 3D scan or the physical part. We confirm the material and density, cut a prototype in 3–7 days, and you test it before committing to production tooling.
What is the minimum order for custom foam inserts?
For CNC-cut inserts there is no tooling, so small runs and even single prototypes are practical. Die-cut production carries a die cost, so it needs enough volume to justify it — usually a few thousand parts.
Can you make foam inserts without a CAD drawing?
Yes. Send us the physical part and we will measure and cut from it. This often gives a better fit than a drawing because it captures real geometry rather than nominal dimensions.
Which foam is best for a custom insert?
It depends on the failure you are trying to prevent. EVA for a precise visible cavity, PU for complex curves and delicate finishes, EPE for economical impact absorption, cross-linked PE where fine cell structure and appearance matter. Tell us the product and route and we will specify it.
Send us your specification
Product weight, dimensions, monthly volume and where it ships. We quote within one working day and will tell you if a cheaper specification would do the same job.
Prefer to talk?
Product weight, dimensions, monthly volume and where it ships. We quote within one working day and will tell you if a cheaper specification would do the same job.