Ethafoam STPE200 packaging foam can be considered for flight case and equipment case protection where a semi-rigid foam is useful for pads, separators, support blocks and case lining. A good Ethafoam flight case insert starts with the equipment and the usable internal case dimensions, not with cutting a cavity first and hoping the item fits.
The aim is to control movement while keeping pressure away from fragile parts such as displays, switches, connectors, lenses and protruding controls.
Why use semi-rigid foam in an equipment case?
Soft flexible foam can work well for light cushioning, but some cases need more structure around the item.
STPE200 can suit:
- base support pads
- side and end blocks
- separation layers
- equipment dividers
- lid protection where appropriate
- protective barriers around hard case walls
- simple cut-to-size inserts
- repeat-use transit cases
It is a semi-rigid, non-cross-linked expanded polyethylene packaging foam. All Foam supplies it in white or grey, in two sheet sizes and online thicknesses from 5mm to 100mm.
Measure the inside of the case, not the outside
External case dimensions do not tell you how much foam space is actually available.
Measure:
- clear internal length
- clear internal width
- clear internal depth
- lid recess
- hinge intrusions
- catches and lock housings
- wheel housings
- handles or moulded ribs inside the shell
Then measure the equipment at its widest, longest and highest points.
The space left between the item and the case has to accommodate the protective foam without forcing the lid closed.
Identify safe support points
Not every part of a product should touch the foam with the same pressure.
Good support areas are usually robust surfaces designed to carry load. Fragile or sensitive areas can include:
- screens
- buttons
- knobs
- connectors
- vents
- lenses
- calibrated components
- decorative finishes
- thin covers or panels
Mark the safe load-bearing surfaces before planning the insert.
A flight case that looks neat can still be badly designed if the foam pushes directly on a vulnerable control.
Weight and contact area matter together
Heavy equipment needs careful support, but weight by itself does not select the foam thickness.
A flat base spreads load across a larger area. Four small feet concentrate the same total weight into much smaller contact zones.
If the equipment has feet, brackets or narrow edges, consider whether the insert needs broader support blocks beneath approved structural points.
For higher loads, read the high load bearing packaging foam guide before choosing the layout.
How much clearance should there be?
There is no universal clearance that suits every item.
The insert needs enough space to provide controlled cushioning without allowing the equipment to gain momentum inside the case.
Too much clearance can let the item move before it contacts the foam. Too little clearance can leave the foam permanently compressed and place unnecessary pressure on the equipment.
Check the complete closed case, including the lid.
Choosing 25mm, 50mm or another thickness
The correct Ethafoam depth depends on:
- equipment weight
- contact area
- fragility
- available case space
- expected drops and vibration
- whether the case is carried by hand or transported as freight
- how frequently the equipment is removed
- the location of each pad
The Ethafoam thickness guide explains why a single "best thickness" answer is rarely responsible.
A case can use different foam depths in different positions when the design requires it.
Base foam and lid foam do different jobs
The base usually carries most of the static load. Lid foam may only need to prevent upward movement or provide light restraint.
Do not automatically use a thick lid block if it presses on the top of the equipment.
When the top surface contains controls or a display, the lid design may need clearance rather than continuous contact.
The case should close normally without excessive force.
Should the insert grip the equipment tightly?
The item should be secure, but "tighter" is not always safer.
An insert that requires force to load can:
- damage delicate surfaces
- tear narrow foam walls
- create excessive pressure
- make field use frustrating
- encourage users to pull aggressively on the insert
Reusable equipment cases benefit from a practical removal method.
Finger spaces, access channels or planned lifting points can make the insert easier to use without weakening critical support areas.
Cut-out cavity or separate support blocks?
Both approaches can work.
A one-piece cavity can give a clean layout where the foam thickness and equipment geometry allow it.
Separate pads and blocks can be useful when:
- the case is large
- only certain surfaces should carry load
- the item is irregular
- different foam depths are needed
- future replacement of individual supports may be useful
For custom pieces, see the Ethafoam cut-to-size guide.
Repeated loading changes the design
A flight case used every week has different demands from a box used once.
Think about:
- how users lift the equipment out
- which foam edges get touched
- whether dirt or oil can reach the insert
- whether tools are returned to the correct location
- whether the case is stored in vans, workshops or warehouses
- whether the equipment configuration changes over time
Inspect the foam regularly for permanent compression, torn walls, loosened pieces and a poor fit.
The reusable Ethafoam packaging guide covers repeat-use checks in more detail.
Moisture and temperature
The current All Foam STPE200 technical data lists water absorption of 1.19% by volume after 24 hours and a working temperature range of -30C to +80C.
Those figures describe the material, not the complete case.
Water can still enter through the case, seams and openings. Adhesives and other materials may also have different temperature limits.
For outdoor or specialist use, confirm the complete system.
Electronics inside flight cases
Physical cushioning does not automatically provide electrostatic protection.
If the equipment contains exposed or static-sensitive electronics, do not assume standard STPE200 meets an anti-static or ESD requirement.
Read Ethafoam for electronics packaging and confirm the required packaging specification.
Is STPE200 fire retardant?
No. The All Foam STPE200 grade is not fire retardant.
If the case is used in an environment with a defined fire-performance requirement, confirm the required material specification before ordering.
Quick answers about Ethafoam flight case inserts
Is Ethafoam suitable for flight cases?
STPE200 can be suitable for pads, separators, support blocks and lining where semi-rigid packaging foam matches the equipment, load and case design.
What thickness should I use in a flight case?
There is no universal thickness. Measure the usable case space and consider equipment weight, contact area, fragility and expected handling.
Can I cut Ethafoam into equipment cavities?
It can be converted into suitable pads and inserts. Complex cases should be planned from accurate dimensions and safe support points.
Should lid foam press on the equipment?
Only where the contacted surface can safely accept the pressure. Fragile controls, displays and protrusions often need clearance.
Is standard STPE200 anti-static?
Do not assume it is. If ESD control is required, use a product with the correct verified anti-static specification.
A practical flight case planning checklist
Before ordering foam, record:
1. internal case dimensions 2. equipment dimensions 3. equipment weight 4. safe support points 5. fragile no-contact zones 6. required access for lifting the item 7. likely transport conditions 8. expected reuse frequency 9. specialist anti-static or fire requirements 10. quantity of cases
This turns the project from guesswork into a repeatable brief.
Build the case around the equipment
The best insert is not simply the thickest foam or the tightest cavity. It is a layout that supports the equipment at safe points, controls movement and remains practical through repeated use.
For standard sheets or a non-standard requirement, view Ethafoam STPE200 and send All Foam the case dimensions, item dimensions, weight and intended use.
