Foam insert
EVA or PE foam200 minimum · 10 to 14 business daysA foam insert is a block of closed-cell EVA or PE foam die-cut with cavities that hold a product with no movement at all. They come from 3/8 to 2 3/8 in thick in black, white or gray, layered where a product has a shoulder, from 200 units in 10 to 14 business days after proof. Most are cut for boxes between 6 by 4 and 12 by 9 inches.
When to choose it, and when not to
Choose a foam insert when the product is glass, metal, electronic or expensive and a rattle is not acceptable. A fragrance bottle, a watch, a pair of earbuds and a cable, a set of knives. Foam holds a product at its exact outline, and black EVA against a printed box is the look most tech and spirits packaging uses. It also works when the box will be reopened many times, because foam does not crease or wear.
Choose a die-cut paperboard insert when the product is light and the insert should print or be recycled with the box, since foam does neither. Choose a molded pulp insert when the brand has a plastic commitment, because EVA and PE foam are plastics and go in general waste.
Specifications
| Board | EVA foam 2.4 to 2.8 lb per cubic foot, or PE foam about 1.9 lb per cubic foot |
|---|---|
| None on the foam, optional printed paperboard top sheet | |
| Finish | Black, white or gray, plain or velvet-flocked |
| Closure | None, friction fit in the box base |
| Insert | Single layer, or two to three layers glued for stepped cavities |
| Thickness | 3/8, 3/4, 1 1/8, 1 5/8 or 2 3/8 in, or a layered build to any depth |
| Minimum | 200 units |
| Lead time | 10 to 14 business days after proof |
| Ships | Placed in the box, or stacked flat in cartons of 25 |
| Sizes we run | cut to fit a 6 x 4 x 2 in box cut to fit a 8 x 6 x 3 in box cut to fit a 10 x 8 x 4 in box cut to fit a 14 x 10 x 5 in box any size from 3 x 3 to 20 x 16 in footprint |
Materials that suit it
Questions people ask
EVA or PE foam?
EVA is denser, around 2.4 to 2.8 lb per cubic foot, holds a crisp cut edge and is what you see in watch and tech boxes. PE is softer, about 1.9 lb per cubic foot, and is the cheaper choice for protecting a product in transit where looks matter less. Both are closed-cell and do not absorb water.
How thick should the foam be?
The cavity should be about two thirds of the product's height so it lifts out easily. A 1 1/8 in foam holds a 1 3/4 in bottle well. Add 3/8 in of solid foam under the cavity as a floor. For a product with a shoulder or a cap, we spec two glued layers with different cutouts rather than one thick block.
Can the foam be a color?
Black, white and gray are stock and cover almost everything. Other colors are possible on EVA at a higher minimum and add about a week. A better route for color is a printed 18pt paperboard top sheet glued over the foam, which gives you full color and hides the foam edge.
Will foam mark the product?
Closed-cell EVA and PE are inert and do not off-gas or leave residue on glass, metal or lacquer. If the product is a polished chrome or a high-gloss lacquer that shows every touch, we recommend the velvet-flocked finish on the cavity, which adds a soft surface and about 3 business days.
Is foam recyclable?
No. EVA and PE foam go in general waste in almost every US program, and we do not print any recycling mark on them. If that matters to your brand, a molded pulp insert does most of what foam does for items under 3 pounds and is recyclable as mixed paper. We will say which fits your product.
How is a foam insert different from a molded pulp insert?
Foam holds tighter and absorbs a harder hit. It is closed-cell EVA or PE foam, die cut with cavities, 3/8 to 2 3/8 inches thick, plain or velvet-flocked, and it is a plastic. The molded pulp insert is recycled paper fiber pressed into your product's shape, recyclable with paper, with an aluminum tool cut once and kept for reorders. Both start at 200 units in 10 to 14 business days after proof. Electronics and luxury glass suit foam; brands with a plastic commitment suit pulp.
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Ready to price your foam insert?
Send the size and quantity for a quote and a dieline, usually within one business day. Your digital proof follows, usually within one business day of your artwork. Design help and the Swatch Book of materials are free.