Our foam inserts are designed to keep the contents of our cases secure and safe. Whether the contents be military, medical, or electronic in nature, foam will keep them in place while the outside of the case takes a beating. So how is foam made? And what makes it so strong?

foam insert packaging

Foam’s strength comes from its chemical composition. To manufacture foam, two chemicals are used: polyol, a complex alcohol, and diisocyanate, a petroleum byproduct which reacts with alcohol. When these two ingredients are mixed and heated they form a liquid polymer called urethane, or polyurethane.

This hot liquid polyurethane is sprayed through a nozzle head onto wax paper that moves on conveyor belt. Carbon dioxide is also sprayed from another nozzle, which causes the liquid to expand and form a foam strip as it moves down the belt, which is trimmed and compressed into a viable shape. There are many gas bubbles in the polyurethane, which have to be released, otherwise the foam will become rock hard. The foam passes over heat lamps that dry the foam and cause the bubbles to expand and pop, which leaves behind spongy porous foam that can be molded into foam inserts.


Advanced Packaging, Inc. was established over 40 years ago with the mission of engineering and delivering the highest quality shipping and cushioning systems available. Since then our worldwide customer base has grown to include those in the military, government, commercial and industrial business sectors, as well as many other industries. API’s local clients value our convenience to the Washington, DC tech corridor.

Not only do we make custom cases for every type of industry, API is also equipped with the latest in quality assurance and process control monitoring technology, including drop testing, protecting your electronic equipment from unforeseen accidents and events. Our team of craftsmen regularly build and then test a variety complex electronic assemblies.

If you have any questions about our Custom Foam Inserts, please contact Advanced Packaging Inc. by calling 1-888-206-5250 or visit our website today!

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