Princeton Case Company
615 Sherwood Parkway
Mountainside, NJ 07092
service@princetoncase.com
(908) 687-1750

How to Design Plastic Carrying Cases with Foam Inserts

No blow molded case is complete until it is fitted with custom foam inserts. Of course, the design of a blow molded case is important, but the foam offers the support needed to protect expensive and fragile gear while traveling. When customizing a plastic carrying case with foam, there are three main things to consider: foam material, foam configuration, and fabrication methods. Below, we want to highlight some of the most important design considerations when customizing foam inserts.

Blow Molded Cases

The two most used foam case materials include Polyethylene (PE) and polyurethane (Ester). Although there are other options, these two are often seen as the best and most cost-effective options. PE foam is a long-lasting and dense material that offers great protection. They are ideal for cases that hold medium to heavy objects. You can commonly find this case being used in gun cases. The material absorbs only a moderate amount of shock without damage.

Ester is softer and more durable than PE, making it great for delicate objects that break with modest impact (think glassware). The material can also be designed in irregular and complex shapes, so the material is used to carry cases for cameras and lenses.

After picking a material, you then need to pick between the design of the foam. The three types include solid, diced/cubed, or convoluted. Solid foam pads are appropriate as lids of cases when you need items to sit flush with the base of the case. Convoluted is soft and sturdy, and it is great for gently securing items.

Blow Molded Cases

For more information on customized plastic carrying cases with foam, you should not hesitate to give us a call.

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Princeton Case Company, Inc.

615 Sherwood Parkway
Mountainside, NJ 07092
(908) 687-1750