Custom Foam Inserts
Whether you order a stock molded case or any Flight Case, Badger Case can modify it into a custom application with a foam interior. Foam comes in a variety of colors, densities, textures, and chemical formulations. Materials include Polyether and Polyester Urethane, Polyethylene, Cross Link foams, and Expanded Styrenes. We determine the best foam material to use by weight and fragility of items. Positioning and cushioning of your items are then customized for each project. Badger Case will use your drawings or product examples to construct a custom foam insert. We then fabricate or make a custom cutting die at our plant. We keep your cutting die lines inventoried for 3-5 years. This allows you to repeat your case order in the future exactly the same way as before.
Foam Fabrication Capabilities:
Fabricated: We laminate sheets of foam together to create cavities for your item. We recommend 2” of foam around the perimeter of the case and 1”-3” between items to secure your items.
Machine Cut Foam: We create a jig or die to your exact item specifications. We then use the custom template to machine cut many pieces of foam in a repeatable shape. There is typically a tool charge to make these.
Custom Foam Materials
Polyurethane: The most common polymer used to make foam. Polyurethane foam has an elastic cell structure. This provides a wide range of cushioning possibilities. This soft, open-cell foam is best for delicate and light weight items.
Poly-Ester/Polyurethane: This is an open cell flexible polyurethane foam. It ranges in density from 1.5# to 6#. It is also available in anti-static formulations.
Poly-Ether/Polyurethane: This is a low cost, resilient open cell foam. It is available in densities ranging from 1# to 1.8#. It is also available in anti-static formulations.
Polyethylene: This closed cell foam will not absorb water or moisture. This firm dense foam meets MIL P 26514, Type 1, Class 2 specs. It's used for heavier products. It is great foam for positioning and cushioning. Polyethylene is impervious to most chemicals.
Crosslink/Polyethylene: This rigid polyethylene has little give. It also is impervious to most chemicals. Available in anti-static formulations. Crosslink is more expensive. When aesthetics and durability are necessary, this is the foam to use. It is available in a variety of colors.
EVA/Polyethylene: This foam is also firm, but with a softer feel compared to Crosslink. It is impervious to most chemicals and available in anti-static formulations. EVA is also more expensive. When aesthetics and durability are a must, consider this foam. Available in a variety of colors.