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Foam Fabrication
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2007-10-14
SCS Cases
 Custom foam case interiors:
We use many different types of foam depending on several things; how heavy an item is, what type of load bearing surfaces we have to support the item being cushioned, how sensitive an item is to shock and vibration (fragile), is the item static sensitive, is the item moisture sensitive. Besides different densities of foam we also use different types of foam like; Polyester Urethane, Polyethylene, Polyether and more exotic foams like; Cross Link, Expanded Polyethylene, dissipative and anti-stat foam. We design cushions around certain specification so as to provide the utmost protection of your equipment while in the case during storage or transit. We have found most of our customers appreciate the idea of being able to do a "visual inventory" of items in the case very quickly, knowing if anything is missing before getting to the training seminar or tradeshow.
Low quantity interior cushions: These are laid up by hand, typically the items being packed will be put into simple rectangular, square or round cavities in the foam cushion.
Water Jet cut cushions: This is the process of cutting foam using a high pressure water stream. The stream of water cutting the foam is about the same diameter as a human hair so the smallest details are easily cut with great accuracy. The cavity walls are straight at full depth unlike the die cut method which leaves the walls slightly concaved. There is no tooling charge, but there may be a computer programming charge. Waterjet programming is easily changed if a item is added, eliminated or changed within the case cushion. This is a good choice for higher quantities of case interiors. Because the machine is cutting multiple cavities or cushion sets at one time there is a set amount of time to run its computer program.
Die Cut Foam cushions: This custom interior is cut from a steel rule die produced to your exact specifications and is cost effective for purchases of multiple cases that require identical foam interiors. Because the process is very quick this is the most cost effective way of producing a lot of foam cushions. It is very difficult to change any of the cavities and most times the tool has to be remade rather than modified. Tooling is relatively inexpensive especially amortized over the life of the product. The finished product is not quite as nice as a waterjet cut cushion.
Types of foam commonly used:
Polyester/Polyurethane: The most common polymer used to make foam. Polyurethane foam has an elastic cell structure which provides a wide range of performance possibilities. This soft, open-cell foam is best for delicate and light weight items. This is open cell flexible polyurethane foam ranging in density from 1.5# to 6#. 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 is generally used with heavier products. It is great foam for positioning and cushioning. Polyethylene is impervious to most chemicals.·
Crosslink/Polyethylene: A rigid polyethylene with little give and is impervious to most chemicals. It is available in anti-static formulations. Crosslink is generally more expensive, but when aesthetics and durability are necessary, they should be considered.
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