How Custom Foam Inserts are Made
A good custom case needs an even better custom foam insert. Custom foam inserts operate to keep everything inside the custom case safe and cushioned. They’re an important part of what we do to make your transit and storage cases better protected. Have you ever wondered how foam interiors are created and what makes them a good option for cushioning even your most sensitive equipment? We’ve got some answers for you!
What are Custom Foam Interiors Made of?
First thing’s first – let’s talk about the composition of custom foam interiors. We use polyurethane foam, which is durable with just enough give. Polyurethane is made from small compounds called polymers. There’s a good deal of chemistry that goes into creating the perfect polyurethane foam. It is also used for other things that require fine threads, such as nylon for pantyhose. Polyurethane products come in four different forms: elastomers, coatings, flexible foams, and cross-linked foams. Most of what we use here are flexible foams.
How are Custom Foam Interiors Molded?
- Liquid – Polymers and occasionally additives are combined together to form polyurethane, which starts out as a hot liquid. The liquid is poured down through a pipe directly into a nozzle where it is sprayed out over wax paper and mixes with carbon dioxide
- Expansion – The carbon dioxide helps the polyurethane to expand and begin to form a foam strip. The original strip doesn’t have much shape, so the ends are trimmed off to help create a viable shape out of the polyurethane foam product.
- Drying – When the foam is first created, it’s much harder than the final product – in fact, it’s about the consistency of a rock if the gasses aren’t released. The foam is heated by lamps on a conveyor belt that cause the bubbles to expand and pop. At that point, you get the foamy, spongy material you’ve come to know of custom foam interiors.
- Cut – Once the foam is created, it is cut to fit into your custom case!
Custom Foam Interiors and Cases from Advanced Packaging
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. If you have any questions, please contact Advanced Packaging Inc. by calling 1-888-206-5250 or visit our website today!
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