In-box foam cutting.
Designing the inside of the box around the product: an interior where every part sits in its own cavity, doesn't move in transit, and looks right when opened.
In-box foam cutting removes the commonest cause of transit damage: void space. Every gap between product and carton lets the product move and take knocks on the way. In an interior cut to the product's dimensions there is no gap — the part seats in its cavity and stays there.
One layer or several
For a single product, a base cushion and a top cap are enough. Where several parts travel in one carton, a layered arrangement is built: each layer carries its own cavities and is specified dense enough to bear the layer above it. In practice that means denser material lower down and softer material on top.
Presentation is a requirement too
The moment the box opens is part of the brand, especially in gift, cosmetics and corporate products. The same level of protection can be delivered in a flocked, velvet-lined or corporate-coloured interior; material choice can meet both protection and appearance.
Which comes first, carton or interior
They are decided together. If you already have a carton, the interior is cut to its internal dimensions. If the carton is also new, the size follows from the product and the interior — which usually means a smaller box, less void fill and a lower volumetric shipping charge.
How We Work
- 01
Measure and assess
We establish the product's dimensions, weight, centre of gravity and vulnerable points, then assess transport conditions and stacking load.
- 02
Material and method
Density and thickness follow weight and drop height; the cutting method follows quantity and geometry.
- 03
Sample and approval
A sample is produced before any production run; cavity depth, fit tolerance and protection are verified on it.
- 04
Production and delivery
Production follows the approved sample and is delivered to schedule; the specification stays fixed when the job repeats.
Materials and Methods
- Polyurethane foam — soft contact, economical
- EVA — high impact absorption, clean edge
- XPE — light, fine cell, presentation quality
- Flocked foam — velvet-textured surface
- Steel-rule die (high volume, repeat work)
- CNC cutting (low volume, complex geometry)
- Waterjet (thick sections and fine contours)
- Horizontal slicing (block to thickness)
Applications
- Electronics boxes
- Medical devices and equipment
- Cosmetics and gift presentation
- Jewellery, watches and accessories
- Spare parts and assembly kits
- Sample and demo kits
- Promotional and corporate sets
- E-commerce order packing
Related Product Forms
Frequently Asked Questions
- Can you make it fit my existing box?
- Yes. Send the internal dimensions of the carton and the dimensions of the items going in, and the interior is designed to fit it.
- Can separate cavities be made for several items?
- Yes. For items shipped as a set, a separate cavity is designed for each — so parts don't knock together and a missing item is visible at a glance.
- Do you produce a sample?
- Yes, and we recommend it. Cavity depth and fit can only be confirmed with the real part in place; a sample makes that check before quantity is committed.
Send your product dimensions and quantity, and our technical team will come back with a lead time and a quote within 24 hours.
Request Quote