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Shipping cases, custom cases, and carrying cases can be made from a variety of materials depending on their durability requirements. Custom foam and the best case construction are essential parts of protecting your sensitive items. That is why gun bags & range mats is essential for the safety of your gun and other items.

Understanding the differences between foam manufacturing methods will help you decide which type of custom foam you need. Below are the best uses and methods of manufacturing custom foam.

DJI Mavic Pro Hard Case with Laser Cut Foam Insert

Die-Cut Custom Foam

The die-cutting process is used to produce large quantities of uniformly designed products (usually more than 25). The company you contract to make your products may use die-cutting if they need large quantities of a particular case to package your product for sale in retail or industrial markets.

Hand-cutting/Band Saw

The Band Saw is a great single-piece cutting method. This is a great tool for prototyping quickly with little detail and few cavities. The pattern image is usually drawn on the underside and then cut using a bandsaw with a low dust foam blade. Each cavity is cut by a skilled technician. 

The technician starts from the outer wall of foam and then exits through the original entry point. After the cutting is completed, the entry point can be glued together.

Water Jet Design

Water jet cutting is a very popular manufacturing technique that uses a high-pressure water jet to make precise cuts and designs.