FOAM QUALITY

How to Choose the best foam for your design

 
 

Base Foam

For the base foam there are three foams available:

ProCell is a High-Density foam with a velvet feel. It has a high-temperature resistance. This foam is not affected by fluids like water or oil. This foam is perfect for heavier objects and is also used for presentational purposes. In Europe, this is the most used foam.

EcoCell is also, a High-Density foam which can be compared to our ProCell. But, it has bigger cell structure and feels a bit more 'dry'. The unique aspect of this foam is that we can recycle 100% of the scrap material. We grind it, melt it to blocks and send them back to the factory for a cradle to cradle use. Because we promote the ecological aspects of this foam we have made it more economical.
 
SoftCell is a soft, Low-Density foam. Perfect for packing lighter objects that need more padding. Think of camera body's, glass or artwork. This foam is just like the EcoCell more economically priced. The foam feels like a sponge and absorbs water or other fluids.
 
So, to sum it up,
It's up to you to choose any of these three options:
 
ProCell is a High-Density foam with a luxurious feel.
 
EcoCell is a recyclable foam with a bit more rough feel.
 
SoftCell has a 'sponge' feel, for the most delicate purposes.

 
Lid Foam
For designs that require foam for a case's lid, we offer two options: Convoluted foam and Solid (flat) foam. Both are SoftCell material. 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.
   
   

CNC Milling

(most used)

For precise 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 automatically to get the best result is a short time. 
Because of the milling process, there will always be some dust residue in the cavities.


Questions?
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: