Engineered foam protection designed around your equipment.
Custom foam does more than fill the space inside a case. When properly designed, it helps control movement, manage shock, organise components and make equipment easier for operators to identify, access and repack.
B&D designs and manufactures bespoke foam inserts, cushions and internal protection around the exact equipment being carried. Foam can be incorporated into cases and containers from across our wider product portfolio or developed as part of a completely bespoke packaging solution.
Every foam project begins with the equipment.
Our team can work from customer CAD data, physical samples or measurements to establish the geometry and protection requirements. Using 3D CAD, the internal arrangement can then be developed around individual components, allowing clearances, support areas and equipment layouts to be considered before manufacture begins.
Where several items need to share one case, the layout can also be optimised to make effective use of the available space.
Different equipment and environments require different material characteristics.
B&D has access to foam grades offering properties including closed-cell and open-cell construction, different densities, enhanced durability, high-temperature performance, flame retardancy and conductive properties.
Material selection is therefore based on the application rather than using a single foam type for every requirement.
For sensitive equipment, foam performance can be considered as part of the wider packaging design.
Cushion thickness and material density can be selected according to factors such as equipment fragility and anticipated handling conditions, helping reduce the shock transmitted to the contents.
The case, foam and equipment are considered together so that the internal solution supports the protection provided by the outer container.
Approved CAD models are used within B&D’s dedicated UK foam manufacturing capability.
CNC cutting and related manufacturing processes allow foam components to be produced accurately and consistently. Finished inserts can then be bonded into cases where required before final quality inspection.
This direct link between design data and manufacture is particularly valuable for repeated units and more complex internal layouts.
Foam can also support the practical use of equipment.
Different colours, layouts and identification features can help operators see where equipment belongs, recognise missing components and return items correctly after use. Logos or other markings can also be incorporated where appropriate.
Disclaimer: Generative Ai may be used on this site when specifically creating content and information relating to the products, processes and materials we use at Polyformes. Any Ai content undergoes stringent reviews and editing by humans to check accuracy. Please view this content policy for further details.
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Send us details of your equipment or the case you need to fit and our team can develop the internal protection around the requirement.
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Our experts
The information on this page was written and checked by our team of experts. You can contact them to discuss your requirements, or for any questions you may have, using the details here.
Andy Harrison
Design Manager
[email protected]
+44 (0)1271 375 197
Mark Speck
Sales
[email protected]
+44 (0)1271 375 197