Foam for Product Boxes - Page 1
Forum section: electronics / general

author: forrestc
author_rank: Unknown
timestamp: October 30, 2017, 01:49:13 pm
content: Sorry for the slightly-OT post, but I figured someone in here will have dealt with this. And since it's about the last step of manufacturing and assembly, I figured it was at least a bit relevant...I get these boxes in all the time with the product being held nicely cushioned in the box with a custom foam insert to hold the product. I'm including a couple of pictures of what style I'm talking about. Always thought they were nice, but no real need for them. There are other similar styles out there (corner pieces, etc).Now that I'm shipping a product in a rackmount enclosure, I'd like to investigate getting some made for this product. So far I haven't found even what magic incantation to put into a search engine to find a manufacturer of these. Preferably in north america, but I'm open to anywhere as long as I can get them delivered for reasonable. Right now we're sticking plank foam squares in a box which is working ok, but is rather expensive from both a raw material and also a time perspective.These look like they're laser or waterjet cut from a big sheet and then the end pieces are glued onto the main piece. Should be rather inexpensive, if I can just find the right vendor.So far I've only found sources for laser cut inserts for cases (like what would go into a hard case), and also a lot of people hocking expandable foam. But not these style or anything similar.Any ideas what these are really called? Or maybe a vendor for them?

author: Kean
author_rank: Unknown
timestamp: October 30, 2017, 01:58:39 pm
content: Something like this?https://www.plastifoam.com/custom-packaging/foam-box-inserts/

author: jpanhalt
author_rank: Super Contributor
timestamp: October 30, 2017, 02:00:34 pm
content: Custom cut foam may be expensive for a few parts. An alternative is "expanding foam packaging bags," for example:https://www.uline.com/Grp_137/Instapak?pricode=WB140&AdKeyword=expanding%20foam%20packaging&AdMatchtype=p&gclid=EAIaIQobChMIsfG05b-Y1wIVgTZpCh0dIAcSEAAYAiAAEgLpP_D_BwE&gclsrc=aw.dsEven Ford uses them to ship parts. They expand to semi-rigged foam and give good protection. Most important, one size -- often 2 bags per box, top and bottom -- fits may different sizes and shapes.That link is just the first hit on Google. I suspect there are many suppliers and some will be cheaper.

author: forrestc
author_rank: Unknown
timestamp: October 30, 2017, 02:58:09 pm
content: Quote from: jpanhalt on October 30, 2017, 02:00:34 pmWe did some experimenting with these and couldn't find a bag size which worked for us without using at least 4 bags per box. Apparently long, flat, and relatively thin (19" x 8" x1.75") is a bad combination since the bags are roughly square.. When we compared the cost of using these to the plank foam, the plank foam won, even accounting for labor.You're right that there are many suppliers, but all of them seem to be hocking basically the same stuff at the same price. In fact, I'm not sure I found a vendor which wasn't selling the 'instapak' brand. There are several (messy) solutions for spraying foam in a box and then putting plastic over it or similar, but those seem to require more volume than we're doing.Part of what is driving this is that our volume is high enough that it's worth it to just get something custom, assuming that custom is not too expensive in the hundreds but not thousands category.

author: Kean
author_rank: Unknown
timestamp: October 30, 2017, 03:03:13 pm
content: So basically a short 1RU enclosure? There should be heaps of solutions off the shelf for that I'd imagine.Did you look at the place I linked above? Maybe call or email them...

author: forrestc
author_rank: Unknown
timestamp: October 30, 2017, 09:25:26 pm
content: Quote from: Kean on October 30, 2017, 03:03:13 pmOops, somehow my reply to you earlier didn't post. Yes, I've already contacted them and they're working on a price. No stock solution apparently. Found another company selling similar stuff using keywords from a few of the descriptions on the website.And yes, a box and foam for a 8 inch deep 1u enclosure. One would think that this would be a standard item somewhere but not that I've found.