Every cubicmillimeterengineered.
Closed-cell polyethylene inserts precision-cut to your CAD geometry — protecting satellite components, surgical robots, and million-dollar optics from the factory floor to final destination.
Numbers before narrative.
Every card is backed by a test report or production record. Filter by your industry to see what matters most.
Across 14,200 custom insert orders in 2024. Each cavity verified against CAD nominal with CMM inspection before shipment.
Measured per ASTM D4169 Cycle II at 30-inch edge drop. Closed-cell PE density 2.0 PCF, 25% compression deflection at 8 PSI.
From single prototypes to 10,000-unit production runs. Average lead time 6 business days from CAD approval.
±0.030 inch on all CNC hot-wire cut cavities. Tighter tolerances available on request with tooling qualification.
From CAD file submission to certified shipment. Rush 3-day service available for defense programs with existing material stock.
Polyethylene 1.2–6.0 PCF, cross-linked PE, conductive PE for ESD-sensitive electronics, anti-static black, and flame-retardant UL94 HF-1.
Full documentation package: material certifications, first-article inspection reports, and packaging data sheets for defense contract compliance.
ISTA 2A and ASTM D4169 drop test protocol. All standard insert profiles pre-qualified. Custom profiles tested on request.
Continuous production for semiconductor clients since 2016. Conductive PE inserts engineered to SEMI standards for 200mm and 300mm fabs.
Specify the right grade.
Not the cheapest one.
Fourteen foam formulations in continuous stock. Each grade is characterized against ASTM D3575 and tested per our internal qualification protocol before entering production. Click any row to see the full data sheet.
From CAD to certified
in six business days.
CAD Intake & DFM Review
STEP / IGES / DXF acceptedSubmit your 3D file or 2D drawing. Our engineers run a Design for Manufacturability check within 4 hours — flagging any geometries that require tooling qualification or density upgrades.
Material Selection & Quote
14 grades, same-day pricingBased on payload mass, fragility class (G-rating), and compliance requirements, we recommend the optimal foam grade and deliver a fixed-price quote with lead time commitment.
CNC Hot-Wire Cut
±0.030" tolerance standardBillet loaded into 4-axis CNC hot-wire cutter. Cavity profiles machined to CAD nominal. First-article CMM inspection on every new part number before production release.
QC, Pack & Certify
MIL-STD-2073 documentationVisual and dimensional inspection per our IQC plan. Full documentation package generated: material certs, FAI report, packaging data sheet. Ships with cert of conformance.
The spec sheet before
the sales call.
Engineering depth first. Every resource below is written by the same team that cuts your foam — not a marketing department. Filter by your vertical to see what's most relevant to your qualification process.
38 pages. Covers all 14 foam grades with cushion curves, ASTM/MIL cross-references, and a worked example for each industry vertical.
No spam. Used only to route your inquiry to the right application engineer.
Foam Density vs. Fragility Class Reference Chart
Quick-reference matrix mapping payload fragility class (Gn) to recommended foam density and minimum cushion thickness for standard drop heights.
Cushion Curve Calculator Tool
Enter payload weight, drop height, and fragility rating. The calculator outputs recommended foam grade, minimum thickness, and expected transmitted G-force.
ASTM D4169 Drop Test White Paper
Technical overview of Cycle II drop-test methodology, cushion curve interpretation, and how to back-calculate required foam density from payload G-rating.
MIL-STD-2073-1E Compliance Checklist
47-point checklist covering packaging data sheets, material certifications, and first-article inspection requirements for DoD contract packaging.
FDA 21 CFR Part 820 Packaging Compliance Guide
How to document foam insert specifications in your device history record. Includes template SOPs for incoming inspection and packaging validation protocols.
ESD Foam Selection Guide for Semiconductor Packaging
Surface resistivity requirements, SEMI standards cross-reference, and foam grade comparison for 200mm and 300mm wafer carrier applications.
Your auditor won't
find a gap.
Six standards. Full documentation on every order. When your packaging engineer writes the spec, and your quality manager signs the DHR, every line traces back to a Shield cert number.
DoD Standard Practice for Military Packaging
All defense contract packagingFull documentation package: PPP-C-843 foam cert, packaging data sheets, first-article inspection reports.
Performance Testing of Shipping Containers
Cycle II — 30" edge drop standardAll standard insert profiles pre-qualified. Custom profiles drop-tested on request with full report.
ISTA Test Procedure for Packaged Products
≤ 150 lbs packaged productVibration, shock, and atmospheric conditioning per ISTA 2A protocol. Certificates issued per shipment.
Quality Management System
Design, manufacture, inspectionRegistered since 2009. Annual surveillance audit. Certificate #US-QMS-2024-4471.
Mechanical Spec for 300mm Wafer Carriers
Semiconductor front-opening unified podsFoam insert profiles for FOUP and FOSB qualified to SEMI E47.1 dimensional and ESD requirements.
Quality System Regulation
Medical device packagingDevice History Record documentation templates, incoming inspection SOPs, and packaging validation protocols available.
We generate a complete documentation bundle — certs, data sheets, FAI reports — with every production order.