Foam Insert Production
In-house foam cutting: CNC routing, die cutting, convoluted and pick-and-pluck layers, EVA and PE lamination.
Three cutting methods
CNC routing handles any geometry and is used for fixed, high-value layouts. Die cutting is faster per piece and is used where a layout will be repeated at volume. Convoluted and pick-and-pluck layers are produced from block stock and are used where the customer needs to reconfigure the interior themselves.
Bonding and layering
Layers are bonded with an adhesive selected for the foam grade and the cleaning agent the case will see. A clinical interior is bonded differently from a depot tool case.
Drawing or sample received
Cutting file prepared and reviewed with the customer
Block or sheet stock selected by grade and density
CNC route, die cut or pluck layer produced
Layers bonded and trimmed
Fitted into the shell and closure checked