Individual & Prototyping Custom Foam Services

Shipping precision equipment is unforgiving: a cavity that is off by two millimetres, or a foam grade that is too soft, shows up the moment the case is dropped on a loading dock. Prototyping is how PACKYON removes that risk before tooling is cut. Here is how a custom foam programme moves from data to a validated, production-ready design.

Phase 1: Structural Mock-up — CNC-cut EVA foam to test internal dimensions and fit

Every custom foam programme starts with a structural mock-up. We take your device envelope and tolerance data, then CNC-cut a full-scale EVA cavity so that your engineering team can physically load the product, check clearances, and confirm cable routing before committing to tooling.

Phase 2: Material & Density Validation — testing different foam densities for shock absorption

The same cavity can be produced in several foam densities, from soft 25 kg/m³ cushioning grades through to firm 80 kg/m³ structural grades. Each variant is assembled and packed the way your product will ship, so the drop performance can be compared side by side under identical conditions.

Phase 3: Drop & Vibration Test — real-world environment simulation

Prototypes are then released into laboratory and field testing: edge drops, random vibration tables, compression and transit trials. Results are documented and returned with recommendations on wall thickness, lid support and lid retention before mass production begins.

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