Foam Cushioning 101

At Cases2Go, we specialize in packaging engineering and take pride in offering virtually endless possibilities for transit case interiors. Our cases are configured to meet an endless set of specialty requirements with engineered foam interiors to fully integrate and protect your equipment. Our high performance packaging solutions utilize a variety of foam materials and configurations for highly sensitive instrumentation, medical equipment, weapons, audio/visual gear and electronic components.

The very heart of our operation can be found in our state of the art twenty-two thousand square foot production facility. Our customers have come to rely on us not only for our sensible and innovative foam solutions, but also our focused response to their urgent and often changing needs. Whether you require a single prototype or thousands of units – our sales consultants work in tandem with design engineers and highly-skilled packaging and manufacturing specialists to produce a design that is right for your application.

Why is cushioning so important?

Custom foam inserts offer the best method for interior protection of equipment. A properly fitted cushioning system will effectively absorb the effects of shock and vibration caused during transit. Based on the equipment specifications provided, our sales specialists and designers can create a custom cushioning system specifically for your items and application requirements.

Types of Foam Materials

Foam selections include a large inventory of closed cell, Polyethylene and open cell Polyurethane foams with density ranges to support light to heavy products. With a wide range of foams available our designers are able to offer our customers a complete package solution which not only protects but looks appealing. Choosing the proper foam material for your requirements

• Polyethylene: (Also referred to as “PE”) Is firm, denser, closed-cell foam, best for general use and heavier equipment. Polyethylene is often used for packaging applications due to its excellent vibration dampening and insulation properties.
• Crosslinked Polyethylene: Is highly dense closed cell foam characterized by its compact feel and resistance to water. It has many of the same properties as polyethylene foam but also has the ability to protect class “A” surfaces and is consequently used extensively in the packaging of medical products and equipment.
• Polyurethane: (Also referred to as “PU”) Is softer, open-cell foam, best for sensitive equipment that is lighter in weight with a high fragility and lower drop height maximums. It is available in two primary types, polyether and polyester, in a range of densities.
• Anti-Static: Available in both Polyurethane and Polyethylene versions. These specials foams inhibit the buildup of static electricity and help dissipate static charge, primarily used for the protection and packaging of sensitive electronic components and products. This offers a lower range of electrical resistance than static dissipative and conductive foams.
• Conductive: A grade of foam that offers the highest level of electrical resistance, and provides excellent EMI shielding. Conductive refers to the material's ability to drain away charges instantly.
• Static Dissipative: A grade of foam in the middle range of electrical resistance, which is greater than anti-static and lower than conductive.
• Poly-Styrene: Commonly known as Styrofoam. Is an ultra-dense foam, which can be molded to customer specifications.

Common MILSPECS:

PPP-C-1752 Type I, Class 2, Color Gray, Density 2pcf (normal) or 4pcf (high density)
MIL-P-26514 Type I, Class 2, Color Gray, Density 2pcf (normal) or 4pcf (high density)

Please contact our sales specialists with your MILSPEC requirements.

Types of Cushioning Systems

Cases2Go specializes in providing solutions for the most complicated case and foam cushioning challenges.

• Foam Filled: The case is filled with separate layers of any one type of the above foams.
• Foam Lined: The case is lined with a layer of any one type of the above foams. (Commonly 1" or 2".)
• Diced Foam Filled: The case is filled with separate diced foam layers, usually polyurethane foam which individual blocks of foam can be removed (pinch and tear) to create desired cavities.
• Custom Cushion: Based on the equipment specifications provided, our sales specialists and designers will create a custom cushion specifically for your items using any one or a combination of the above foams. Our precision fabrication capabilities enable us to provide unparalleled accuracy and quality for custom designed case interiors.

Custom Cushioning Options:

• Straps (Woven or Velcro): Commonly used to secure items in a lid cushion. Woven straps can also be used in conjunction with a lift out tray to provide easier access to compartments below.
• Lift-Out Tray: Maximize available depth, compartments and configuration options.
• Hard Partition: Spreads equipment load; protects and supports compartments.