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Different Methods For Manufacturing Custom Foam Interiors For Transit Cases

Shipping cases, custom cases, and carrying cases can be made from a variety of materials depending on their durability requirements. Custom foam and the best case construction are essential parts of protecting your sensitive and valuable items.

Understanding the differences between foam manufacturing methods will help you decide which type of custom foam cutting for hard cases you need. Below are the best uses and methods of manufacturing custom foam.

50" Double Rifle Bag - Black

Die-Cut Custom Foam

The die-cutting process is used to produce large quantities of uniformly designed products (typically more than 25). The company you contract to make your products may use die-cutting if they need large quantities of a particular case to package your product for sale in retail or industrial markets.

Hand-cutting/Band Saw

The Band Saw is a great single-piece cutting method. This is a great tool for prototyping quickly with little detail and few cavities. The pattern image is usually drawn on the underside and then cut using a bandsaw with a low dust foam blade. Each cavity is cut by a skilled technician. The technician starts from the outer wall of the foam and then exits through the original entry point. After the cutting is completed, the entry point can be glued together.

Water Jet Design

Water jet cutting is a very popular manufacturing technique that uses a high-pressure water jet to make precise cuts and designs. You can cut anything if you can draw it in CAD. For quantities below 25, the water jet can be very economical. It can easily cut intricate configurations, small cavities and large numbers of cavities. Contrary to what was previously mentioned, the band saw can be slow, tedious, and difficult for small details. The foam is also penetrated by water jet directly, eliminating any entry points from the side walls.

This creates a weak spot. The final product is extremely strong and durable and can be used for tradeshow and sample purposes. Water jet processes have different drying times depending on the foam type and the drying process used by the fabricator. This should be taken into account when calculating the receipt of goods deadlines.