Foam quality

Foam - How to Choose the Right Custom Foam

Your foam is your design's canvas.

Base Foam

We have many different foams available. The most comon used foam is a cross linked foam from Seikisui Alveo. We use the NA36 quality. 
We have the option to use oter quality or colors foam. Feel free to contact us with any requirements!
NA36 has a soft touch. Because of the small dark grey/ black cells it has a luxury look. The foam is oil resistant, low water absorbtion and can withstand heat untill 110 degrees celcius.
Untill 30 kilograms it is fair to use this quality. Above 30 kg it is better to look at even a higher density. Contact us to quote you.

Lid Foam
For designs that require foam for a case's lid, MyCaseBuilder offers two options: Convoluted foam and Solid (flat) foam. Convoluted foam (also known as egg-crate foam) is the standard for lid foam, offering suitable protection while securing case items in place. It is also recommended for designs where items may protrude from the Base into the case lid. Solid Foam is much less widely used, appropriate only for cases with very shallow lids (under 15 mm), or for designs where all items sit flush with the surface of the base foam. Of course, since you're the designer the choice is yours!

Foam Fabrication Methods

Once your design is complete and your order is placed, it's cutting time. Our factory is outfitted with many computer-controlled precision cutting machines and we employ the right one for each job to ensure your case foam comes out perfect.

Foam Cutting Methods
Water-Jet Cut
Nothing matches the speed and accuracy of our double-headed Water Jet cutter. This machine cools, compresses and streams a high-powered 0.5mm wide jet of water that cleanly slices even the most durable foams we offer. Every intricacy of your custom foam design will be picked up by the ultra smooth movement of the jet nozzle, resulting in a perfectly replicated custom cut foam insert.
Knife Cut
For creating prototype samples, fabricating small cases and handling production runs under 25 pieces, an exacting knife cut is the way to go. Our computer-controlled knife cutter is capable of serially producing multiple jobs from a single plank of foam.

When needed, this machine also employs a routing bit for "drilling" cavities, resulting in the creation of a glueless, continuous piece of foam.
For the most professional look, foam can be custom cut using steel-rule dies and our in-house die-cutting presses. Die-cut foam is precision sized and smoothly shaped so your items will fit perfectly. From the smallest holes to the tightest curves, die-cut foam is the ultimate choice for optimal protection and look. Die-cutting is the usual fabrication method of choice for large-quantity runs and requires a one time tooling charge.

CNC Milling

(most used)

For precies cavities we use a CNC router. This router is strong in different cavity depths. Do keep in mind that because of the round router bits there is always a radius in every corner of about 5 mm. Our machine changes tool automaticly to get te best result is a short time. 
Because of the milling process there will always be some dust residu in the cavities.

As with all aspects of MyCaseBuilder, if you have any questions we encourage you to contact us so we can help you make the perfect case.

MyCaseBuilder tutorial

How to design your perfect foam: