Custom foam inserts are essential for crafting personalized protective cases tailored to your items. Various cutting methods exist for custom foam inserts, each producing unique results to suit different needs.

Water-Jet Cutting for Precision Foam Inserts

Water-jet cutting is the fastest and most precise method for creating custom foam inserts. Using high-pressure water, this technique accurately slices through durable foam materials. With ultra-smooth nozzle movements, water-jet cutting crafts intricate, high-quality foam inserts ideal for protective cases.

Die Cutting for Professional Foam Inserts

Die cutting delivers a polished, professional finish, ensuring foam inserts are precisely sized and smoothly shaped. This method is perfect for creating snug fits for small or curved items. Die-cut foam inserts are commonly used for high-volume production, making them a go-to choice for large-scale case manufacturing.

Wire Cutting for Deep and Large Foam Inserts

Wire cutting is ideal for cases requiring extra depth or larger custom foam inserts. Advanced computer-controlled abrasive wire cutting can create inserts for cases up to 50 inches thick. Note that wire-cut foam inserts typically involve a one-time programming fee.

Knife Cutting for Prototypes and Small Runs

Knife cutting is often used for prototyping or small-batch production, typically yielding up to 25 pieces. This method employs computer-controlled knife cutters to precisely carve shapes from a single foam plank, making it suitable for creating detailed, small-scale foam insert designs.