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custom foam inserts for cases and boxes for protection and promotional presentation or product samples
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custom foam inserts for cases and boxes for protection and promotional presentation or product samples
aluminium reps sample case with custom foam insert to hold payment terminals
black customised plastic sample case including foam insert for distributor sales demo
black peli storm im2400 heavy duty case with folding handles and secure catches
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iM2435 office divider case with telescopic handle and wheels with padded divider set insert
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Custom Foam Inserts for Sample Cases & Presentation Boxes

(1 customer review)

At PottertonPacs we work with businesses to provide foam conversion and custom foam inserts, delivering precision cut bespoke foam inserts designed and CNC cut to the exact specifications of your products or equipment.  Our expertise lies in creating custom foam inserts to protect, organise and present your products. Whether your business is sales and marketing, manufacturing or industrial engineering we can produce a bespoke foam solution to meet your needs. 

We work regularly with professional clients requiring both high-volume and smaller scale requirements of tailored protective packaging and presentation solutions.

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Description

Our custom foam inserts generally are used as solutions for: 

Minimise damage, maximise efficiency and protection.

Precision-engineered custom foam solutions, design and manufactured to provide your business with a scalable packaging and presentation solutions. Discounts are volume based with bulk quantities available for all options, so whether you require a promotional presentation solution, protective enclosures or presentation cases for luxury sample goods then look no further. 

Our  custom cut foam inserts are engineered to provide robust protection and professional presentation for manufactured products. Designed to significantly minimize the risk of damage from shock, vibration, and handling during transit, our custom foam solutions help manufacturers safeguard product quality and enhance brand presentation. Ideal for integration into production and packaging workflows, our foam inserts support both industrial-scale packaging and promotional presentation needs.

  • Orange-Nanuk-Case-with-custom-cut-foam-insert-for-product-samples
Foam Converters & Engineering Specialists for Presentation Solutions

Custom Cut Foam Inserts, Pads & Sheets

PottertonPacs are foam converters & engineering specialists and have a vast range of options for customising the interiors of our folders, bags and cases for high-end presentation solutions.

Custom-cut foam can be specifically and precisely cut to house expensive equipment, delicate precision instrumentation or sample products, explicitly reducing damage causing movement during transportation and consequently also creates a generally further enhanced product presentation to simultaneously showcase your products quality and your companies attention to detail.

Foam interiors are not the only solution on offer either, we also offer custom stitched, moulded and fabricated interior solutions. (minimum quantity or design/tooling fees may apply)

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  • Peli_Case_Electronic-Test-Equipment-Housed-within-Orange-Peli-Case-with-Custom-Foam-Insert

Industries Leveraging Precision Foam Inserts

With one of the broadest ranges of bespoke interior solutions on the market, we are confident we will be able to propose a sophisticated custom interior solution to suit your industry needs. Some of the industries we cater for include:

  • Sales & Marketing
  • Storage & Transit Packaging
  • Electronics, Test & Measurement
  • Industrial & Engineering
  • Medical & Scientific
  • Aerospace & Military
  • Lighting & Audio Visual
  • Construction & Home Improvement
  • Manufacturing

 

Why not speak with one of our experienced team regarding foam conversion or any other custom interior option that could offer a solution to your exact specifications and volume requirements? We would be happy to answer any of your questions or recommend a possible solution for you to consider.

Our Processes

Whether your custom interior requirement is for the protection or presentation of your samples, high end products or equipment, our manufacturing facilities enable us to consistently produce custom-cut foam inserts and bespoke high-end presentation solutions to the highest standard.

We utilise our in-house CAD technology to produce high volumes of consistently precision cut CNC routings, water jet or die-cut protective foam inserts and attractive product presentation solutions for customers with existing outer packaging as well as for customers sourcing new case or bag requirements with us. Some of the technologies and processes we use include:

  • Cad Engineering
  • CNC Routing Foam
  • CNC Waterjet Foam Cutting
  • Bandknife Cutting Sheets, Panels & Foam Pads
  • Die Cutting/Stamping/Press Cutting Foam Inserts
  • Heat Lamination & Butt Welding
  • Stitching Or Fabricating Product Display Boards
  • Digital Printing, Silk Screen Printing, Embroidery Branding & Logo Options
  • Including Branding Or Logo’s Within The Foam Insert
  • Full Colour Digital Print Or Silk-Screened Display Panels & Product Identity Masks

Materials Used

Plastazote is a closed-cell, cross-linked polyethylene (PE) foam.
Key Properties: Lightweight and impact-absorbing, high performance and temperature resistance, chemical resistant, including oils, grease, and alcohol, water resistant and durable, flexible with multiple density and colour options

Plastazote is available in Low (LD) and High (HD)  density options.  The LD range of plastazote is a well-known and popular protective presentation foam solution which is available in 8 various densities of which we see LD18, LD33 and LD45  most commonly used for manufacturing case inserts.

PE Block Foam is a closed-cell, cross-linked polyethylene foam.
Key Properties: Lightweight construction, superior shock absorption, excellent insulation qualities, high durability against wear and tear, temperature and chemical resistance and water resistance. Available in 3 densities with selected options having a variety of colour choices.

Ethafoam, Stratocell, and Polylam  (also known as Jiffy Foam) are open-cell, non-cross-linked polyethylene (PE) foams that offer economical packaging solutions.
Key Properties: Lightweight construction, medium density, strong and resilient, excellent shock absorption, effective vibration dampening, long-lasting protection. Available in black or white plus an anti-static pink option. Ideal for applications requiring cost-effective, durable protective packaging with extended lifespan. 

Polyether Polyurethane HLB22 Foam (PU Foam) is an open-cell, cross-linked polyurethane foam designed for presentation and packaging applications.
Key Properties: Medium durability, high impact resistance, lightweight construction, dark grey base colour.
Common variations: Plain grey foam, eggbox foam and profile foam

  • Can be supplied with a variety of fabric-faced finishes, including brushed nylon tops. Available in various colour options.
  • We can also supply flock-topped or suede/suedette-topped versions which are commonly used within luxury presentation packaging boxes.  

Ideal for inserts for use or within product presentation cases, packaging or sample boxes. 

We supply all of the above foams in sheet and pad form as well as fully customised interiors or fabricated parts.

Gallery

To help visualise what is achievable with the flexibility foam conversion, why not take a look through the gallery of images of previously supplied foam projects shown opposite.

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Reviews (1)

1 review for Custom Foam Inserts for Sample Cases & Presentation Boxes

  1. Rachel –

    We have been a customer for many years and always recieve excellent quality and service. PottertonPacs will always try and deliver earlier if they can and support their customers throughout.

    • Dawn –

      Thanks for your positive feedback Rachel and continued custom.
      Regards PottertonPacs Ltd

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