Foam Inserts for Boxes & Cases — Althor
You've got a product that needs protecting — and you've probably already learned the hard way that bubble wrap and crumpled paper only go so far. Foam inserts for cases and boxes exist for exactly this reason. And when it's done right, the insert does more than protect the product. It communicates quality. It says: we thought about this.
At Althor, we supply packaging foam inserts for businesses across the USA — from small-batch product sellers to industrial manufacturers who need thousands of units shipped without a scratch.
The Foam Types — and What Each One Actually Does
Not all foam is the same. Honestly, this is where a lot of buyers go wrong — they order generic foam and wonder why it doesn't hold up. Here's a plain-language breakdown:
Polyurethane (PU) foam — The most common, open-cell structure, great for light cushioning; used in electronics, medical kits, and display boxes
Polyethylene (PE) foam — Closed-cell, firmer, water-resistant; ideal for tools, instruments, and anything exposed to moisture
Expanded Polystyrene (EPS / Styrofoam inserts) — The rigid white stuff; excellent for shipping fragile or temperature-sensitive items
Pick-and-pull grid foam — Pre-scored foam blocks where you pull out cubes to create a custom fit without any cutting tools
Convoluted (egg crate) foam — Textured surface for even load distribution; good for multi-item packaging
Each material has a specific use case. If you want a full breakdown of which foam type fits which industry, this guide to custom foam packaging inserts for USA buyers covers the materials, types, and applications in detail — worth reading before you spec your order.
What We Offer at Althor
Whether you need foam package inserts for retail packaging, hard-shell cases, or industrial shipping boxes — we've got the fabrication methods and materials to match:Insert TypeBest ForCutting MethodDie-Cut Foam InsertsHigh-volume, repeatable shapes Die cuttingCNC-Cut Custom FoamComplex shapes, tight tolerances CNC routingPick-and-Pull FoamQuick custom fit, no tooling cost Pre-scored gridConvoluted Foam LinersMulti-item protection, even cushioning Sheet cutWaterjet-Cut FoamDelicate or intricate profiles Waterjet precisionEPS / Styrofoam InsertsHeavy or fragile item shipping Molded or cut
Who's Ordering Foam Packaging Inserts From Us?
More industries than you'd expect. From what we see across our USA customer base:
Electronics manufacturers — Boards, instruments, and testing equipment that can't arrive with a single ding
Medical device companies — Surgical kits, diagnostic tools, specimen transport — where insert fit is often a compliance issue
Defense and firearms — Hard-shell cases with precision-cut foam inserts for weapons and accessories
Tool and equipment suppliers — Presentation-quality cases with foam-cut layouts for field kits
Cosmetics and retail brands — Unboxing experience matters; foam liners in gift boxes make a statement
Industrial shippers — Custom sponge inserts for boxes that protect machined parts during transit
Custom vs. Stock Foam Inserts — Which Do You Need?
This is sort of the first question you should ask yourself. Stock foam inserts are faster and cheaper upfront. Custom foam inserts are better for anything with an irregular shape, high-value contents, or a branding requirement.
But here's the thing — custom isn't always as expensive or slow as people assume. Die-cut tooling costs have come down significantly, and CNC-cut foam doesn't require tooling at all. If you're ordering 50 units or more, custom usually pays for itself within one or two production runs. Less product damage, better unboxing presentation, fewer returns.
Speccing Your Foam Insert Order — What to Know First
Before you request a quote for foam inserts for cases or boxes, have these details ready:
Box or case dimensions — Interior length × width × depth (not exterior)
Product dimensions and weight — Especially if it's irregular or multi-piece
Foam type preference — PE, PU, EPS, or pick-and-pull? (Or let us recommend)
Quantity — Prototype run vs. production volume changes the cutting method
Cutting method preference — Die-cut, CNC, or waterjet
Color — Standard charcoal/black, white, or custom color?
Any compliance needs — Anti-static, fire-retardant, or FDA-contact requirements
Well, actually — if you're not sure about the foam type, just tell us what you're shipping and the environment it's going into. We'll work backward from there.
FAQs
What's the difference between foam inserts for cases and foam packaging inserts?
Mostly context. Foam inserts for cases typically refers to precision-cut inserts for hard-shell cases — think equipment cases, gun cases, or presentation cases. Foam packaging inserts is the broader term covering any foam liner or insert used inside a shipping or retail box to protect contents during transit.
Are styrofoam inserts the same as EPS foam inserts?
Sort of. "Styrofoam" is technically a Dow Chemical brand name, but it's become shorthand for expanded polystyrene (EPS) foam in general. EPS/styrofoam inserts are rigid, lightweight, and excellent for temperature-sensitive or heavy fragile items. They differ from soft polyurethane foam, which is flexible and better for surface protection.
Can I get custom sponge inserts for boxes without a large minimum order?
Yes. CNC and waterjet cutting don't require expensive die tooling, so small-run custom sponge inserts for boxes are genuinely cost-effective — even for prototype quantities. For larger volumes, die-cutting brings the per-unit cost down further.
What foam is best for electronic equipment packaging?
Polyethylene (PE) foam is the go-to for electronics — it's closed-cell (won't absorb moisture), offers consistent cushioning, and is available in anti-static formulations to protect sensitive components. Polyurethane is softer and fine for lighter electronics.
How long does it take to get custom foam packaging inserts?
Turnaround depends on cutting method and quantity. CNC-cut inserts often ship within a few business days of approved dimensions. Die-cut production requires tooling lead time but is faster for large runs. Contact Althor directly for a current lead time on your specific requirement.
Bottom Line
If you need foam package inserts that actually protect your product — whether it's a one-off custom build or a high-volume production run — Althor has the materials, the fabrication methods, and the USA-based expertise to get it right. Don't settle for generic foam that leaves your product rattling around a box. Get your custom foam insert quote at Althor today.