Packaging Foam Inserts

At Aerofoam Ltd, we specialize in creating custom packaging foam inserts that offer superior shock absorption, vibration dampening and aesthetic appeal. Whether you need custom shadow boards for tool control, flight case inserts for audio-visual equipment, or presentation packaging for luxury goods, we have the solution.

We utilize precise die-cutting, CNC routing and waterjet cutting techniques to create complex cavities that perfectly match the contours of your items. We work with a variety of packaging foams, including Polyurethane (PU), Polyethylene (PE) and Cross-Linked Polyethylene (XLPE), ensuring the right level of protection for every application.

Our Protective Foam Solutions

Custom Case Inserts
Bespoke foam routing to fit Pelican cases, flight cases and protective hard cases perfectly.
Shadow Boards & Tool Control
Two-tone foam inserts for 5S lean manufacturing environments, ensuring tools are organized and missing items are easily identified.
Presentation Packaging
High-density, smooth-finish foams used for premium product displays, promotional kits and luxury retail packaging.
Anti-Static (ESD) Foam Inserts
Specialized pink or black anti-static foam designed to safely store and transport sensitive electronic components.
Die-Cut Foam Parts
High-volume, cost-effective die-cutting for standard packaging components, end-caps and protective profiles.

Why Choose Custom Foam Packaging?

Maximum protection against impact, drops and vibration
Enhanced unboxing experience for your customers
Professional organization and inventory control
Lightweight solutions that minimize shipping costs
Available in various colors and densities

Secure your products with premium custom foam packaging.
Contact our team today to discuss your design requirements and request a sample.

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Request a Quote or Sample

Tell us your requirements and our team will respond within 24–48 hours with a tailored solution.

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CAD Drawing / Sketch Accepted: PDF, DXF, DWG, JPG, PNG (max 25 MB)

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Foam Grades Wanted *

RICHGUARD® RX — Standard CMHR Polyether

RICHGUARD® RG — High Resilience (HR)

RICHBOND™ RB — Bonded Chipfoam

CELSIUS® VC — Memory Foam (Visco-Elastic)

Other

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FAQs

Frequently Asked Questions

What type of foam is best for packaging inserts?

For heavy or highly valuable items, closed-cell Polyethylene (PE) foam is best as it is rigid and highly impact-resistant. For lighter, delicate items, open-cell Polyurethane (PU) foam provides excellent shock absorption and cushioning.

Can you make shadow boards in multiple colours?

Yes. We specialize in two-tone shadow boards (e.g., a black top layer with a red base layer). This provides immediate visual identification when a tool is missing, which is a key requirement for 5S lean manufacturing environments.

Do you supply anti-static (ESD) foam for electronics?

Absolutely. We supply both pink (dissipative) and black (conductive) anti-static foam inserts. These are essential for protecting sensitive electronic components, circuit boards and hard drives during transit.

What do I need to provide for a custom insert?

Ideally, we need a CAD drawing (DXF/DWG file) of the items you want to pack and the internal dimensions of your case or box. If you don't have CAD files, you can send us the physical items or case and we can design the insert for you.

Do you have a minimum order quantity for packaging foam?

We cater to both small and large requirements. Thanks to our CNC routing capabilities, we can produce single bespoke inserts for a specific flight case, right up to thousands of die-cut inserts for retail packaging.