The four foams we cut
| Material | Thickness, mm | Thickness tolerance | Price | When to use |
|---|---|---|---|---|
| Non-cross-linked PE, gas-foamed, white | 10, 20, 30, 40 | some variation | lowest | Boxes, transport inserts, runs, test samples |
| Cross-linked PE, Ukraine | 5, 10, 20, 30, 40, 50 | +2…+6 | medium | Tools, safes, production and transport inserts |
| Cross-linked PE, Hungary | 5, 10, 20, 30, 40, 50 | 0…+2 | medium+ | Cases, firearms, optics, drones — where looks matter |
| PE + EVA, laminated | 20, 30, 40, 50 | −2…+5 | higher | Premium cases, displays, sharp contours |
Colours from stock: black, grey, white. Thicker and two-colour inserts are made by bonding layers.
What they have in common
All four are closed-cell foams. That means they:
- do not absorb water or oil — they can be washed;
- do not crumble or shed dust like polyurethane foam;
- keep the cavity shape for years and do not wear out from repeated removal;
- are chemically neutral to the finishes of firearms, optics and electronics;
- are light: an insert for a large case weighs hundreds of grams, not kilograms.
How they differ
Non-cross-linked PE (gas-foamed) is the cheapest. White, matt, multi-layer (layers are heat-laminated and do not separate), with sealed bubbles visible in the cut. The surface is flat, slightly wavy. Softer than cross-linked PE. The working material for boxes and anything inside packaging rather than on show.
Cross-linked PE is denser, with a fine even structure, a clean cut and consistent colour. It holds a sharp cavity outline. The Ukrainian grade is more affordable, with larger thickness variation; the Hungarian grade has a consistent texture and thickness. The main material for cases.
PE + EVA is a layer of EVA (dense foam with a smooth skin) laminated to cross-linked PE. It gives the look and feel of EVA at a price closer to PE. For firearm, optics and drone inserts, display and gift sets.
How we choose the material
- Where the insert lives — inside a box (not on show) or in a case (seen every day)?
- What it holds — heavy and hard (firearms, tools) or light and fragile (optics, cosmetics)?
- How many cycles — taken out once when unboxing, or a hundred times a day in a workshop?
- Budget and quantity — a single case or a run of thousands of boxes?
The answers give the material and thickness; a quote usually shows 2–3 options with prices.
Not only foam
For bases, holders and housings we combine foam with other materials:
- ABS plastic 3 mm — milled and bent: pistol holders for safes, shadow board panels, insert bases, trays.
- Plywood, chipboard, wood, PVC — CNC-cut: insert bases, box housings.
- Sheet metal — laser cutting, bending, welding, painting: boxes, brackets, racks.
Samples
We send material samples with the first test insert or separately — tell us what you plan to put in, and we suggest 2–3 options.