| Like so many other things, shipping cases, | | | | uniformly strong and exceptionally durable and |
| carrying cases and custom cases can all be | | | | presents well for sample and tradeshow needs. |
| manufactured using a variety of different | | | | The water jet process does have a drying time |
| materials based on your durability needs. For | | | | that varies on the type of foam and the |
| maximum protection custom foam combined with | | | | fabricators drying procedure and should be |
| the right case construction is an integral part of | | | | considered when calculating receipt of goods |
| the packaging of your valuable and sensitive | | | | deadlines. |
| items. | | | | Contour Saw Manufacturing |
| By understanding what each of these different | | | | Many manufacturing firms – and custom foam |
| foam manufacturing methods has to offer, you | | | | designers – use contour saws for their |
| can gain a better understanding for which type of | | | | flexibility and ease of use. Contour saws allow the |
| custom foam is right for you and your packaging | | | | designer to apply razor sharp precision to their |
| needs. Different methods for manufacturing | | | | foam. Contour Saw is also an excellent choice for |
| custom foam – along with their best use – | | | | small quantity production. While the detail |
| are outlined below. | | | | capabilities are better than band saw it does not |
| Die-Cut Custom Foam | | | | have the capability that water jet has. One of the |
| Die-cutting is used to create large quantities | | | | big advantages is that you don’t have to deal |
| (typically over 25) of uniformly designed products. | | | | with drying of the foam. Contour saw may be |
| If your organization is going to require a large | | | | limited to foam thickness. |
| number of a particular case for packaging your | | | | CNC Router Machining |
| product for sale in the industrial or retail markets, | | | | A CNC (computer numerically controlled) machining |
| the company that you contract to manufacture | | | | tool is a highly automated system that utilizes |
| them may very well use die-cutting for its | | | | CAD designs and computerized data |
| efficiency and cost saving benefits. | | | | configurations, as opposed to manufacturing |
| Band Saw/Hand-cut | | | | manually. The computer driven machinery results |
| Band Saw is an excellent single piece cutting | | | | in consistent and uniform quality and design. |
| method. It’s perfect for quick prototypes | | | | CNC Router is best suited for firm foams. |
| with minimal detail and few cavities. Typically the | | | | Hot Wire CNC Foam Cutting |
| pattern image is drawn on the underside of the | | | | CNC Hot wire foam cutters are popularly used in |
| foam then cut with a band saw with a special low | | | | manufacturing to achieve precise, customized |
| dust foam blade. A skilled technician cuts each | | | | results from semi-rigid foams. Often used in |
| cavity entering from an outer wall of the foam | | | | fabricating architectural products such as crown |
| following the pattern and exiting back through the | | | | moldings and columns, hotwire foam cutters work |
| original entry point. Once the cutting is complete | | | | well with EPE and EPP foams. |
| the entry point is glued back together. | | | | Self-Configuration Options |
| Water Jet Design | | | | When time is of the essence and your |
| Water jet cutting is a popular manufacturing | | | | presentation and protection needs don’t |
| method that involves using a high pressure jet of | | | | require custom foam, self-configuration options |
| water to perform precision cuts and designs. If | | | | like using a utility knife or electric knife to cut solid |
| you can draw it with CAD you can cut it. Water | | | | layers of foam or using pre-cut “pick 'n' |
| jet is very cost effective for quantities under 25. | | | | pluck” foam are a practical approach. |
| The huge advantage is that it can cut extremely | | | | Considering the preceding information, when it |
| detailed configurations, very small cavities and a | | | | comes to protecting your important equipment |
| large number of cavities with ease. Whereas | | | | and products you have many foam options. |
| previously discussed band saw is time consuming, | | | | Today's shipping case interiors can be designed |
| tedious and very difficult when it comes to tiny | | | | using many truly sophisticated methods of |
| details. Water jet also directly penetrates the | | | | custom designed foam, creating the most |
| foam eliminating the entry point from a side wall | | | | formidable kinds of protection and security for |
| creating a week spot. The end product is | | | | even the most discerning organizations. |