Customizing Shipping Case Foam
In an attempt to make your foam customization
Easier, here are some easy to follow, step-by-step
Foam cutting instructions.
Here are detailed instructions on
custom cutting solid foam layers,
customizing pick-n-pluck or perforated foam sheets,
and how to repair damaged foam.
How to Cut Solid Foam Layers
First, remove the foam within the case, with the exception of the bottom layer, and the foam in the lid. These layers will be the top and bottom foam protection for your equipment.
Now take the next layer of foam (from the bottom), and isolate it from the other layers. This layer will act as a template for the layers to follow. Place your item(s) on top of this layer, in accessible and convenient positions.
NOTE: Please remember that you will want access to your equipment from above; all the following layers must allow for this.
Once your item(s) are placed, trace their outlines using a sharpie, magic marker, grease pen, or sharp piece of chalk.
Before cutting, you will need the right instrument. A serrated edge knife, electric carving knife, or a firm extending blade box knife will work well. Use a constant slicing motion, not a sawing motion. Sawing the foam will result in ragged edges. An assistant holding the foam taut and flat will help to make a smoother cut.
When cutting sharp angle corners, it is best to complete your initial cut to the cornered edge. Then approach the same corner from the other side of the angle. Once the cavity has been completely cut out, place your item(s) within the
modified area to test the fit. Your equipment should fit snugly, without compressing the foam more than 1/8"-1/4".
The final steps are the easiest. Determine the order of the layers, and how they will fit in the case. Then apply a thorough coating of spray adhesive, or hot glue between the layers. Use a contact adhesive for ester urethane foam, as this style foam is not as resilient as polyethylene foam.
Adhering the layers together in this fashion prolongs the durability of the foam; each layer should be correctly aligned for convenient item placement and removal.
How to Customize Pick and Pluck Foam
Remove all the pick and pluck perforated foam from the case, leaving the solid sheet in the bottom and the convoluted sheet in the lid.
Arrange all the items on the bottom layer leaving adequate padding around items. Leave a minimum of 1" foam around items, 2" or more may be desired depending on the items fragility and weight.
When satisfied with the layout, begin to trace around the items with a sharpened piece of chalk. Toothpicks may also be used to mark the perimeter of the foam to be removed.
When ready, start removing foam carefully and slowly, as to remove the whole plug in one piece.
NOTE: Do not discard the foam plugs you have removed from the holes.
Put the foam sheets back into the case and place the items in their cutouts. Notice how the items fit, you want a snug fit but not to the point the foam is compressed. Don't worry if the hole is too big or the item sits too deep in the hole.
You can trim the plug (you saved) and simply glue it back in
correcting big holes or raising the item up to the desired level.
With care and planning you can customize the foam inside your case to perfectly hold the items you want to ship.
How to Repair Damaged Foam
If you simply need to glue a piece back in or mend a tear,
simply glue it back together, use the least possible amount of glue possible to prevent hardening of the foam.
If your foam has seen better days and can't be mended or if
you have changed the contents of the case you can get a complete replacement set of foam.
Contact justCASES Toll Free at 888-318-5878 for pricing and availability.
To glue the foam use a contact adhesive for polyester foam, available at most art, hobby, and office supply stores. It is also possible to use hot glue and spray adhesives when in a pinch. Apply the contact cement to both pieces of foam and wait a few seconds. When the cement is tacky, press the foam pieces together and hold for 30 seconds.
NOTE:
If you have a bunch of cases to customize ask us about custom die-cut foam sets. This process cuts out the pattern in the foam for a perfect, consistent cut over all the sheets. However it is the cost of the cutting die(s) that makes this process prohibitive in small quantities. Contact us Toll Free at 888-318-just (5878) for a custom die-cut foam quote.
Top of Page
If you have suggestions or comments about this page please send an email to info@justCASES.com
