The All Foam packaging foam sheets range includes materials for case lining, shaped inserts, lid cushioning and equipment protection. Foam inserts keep tools, instruments and equipment separated during storage and transport. The best foam depends on the value and weight of the items, the case depth, whether moisture resistance matters and whether sensitive to static electronics are involved.
A toolbox drawer insert and a flight case for delicate equipment may use different grades. Start with the application, then choose thickness and cutting method.
Choose the insert by the job
For general tools and drawer organisation, flat packaging foam or closed cell polyethylene are useful starting points. Choose antistatic foam for relevant sensitive electronics, and consider Ethafoam or reconstituted foam for heavier equipment. For lid cushioning, use a suitable current flat foam thickness or shaped cushioning arrangement rather than assuming a profiled sheet is required.
What should a foam insert do?
A useful insert should:
- stop items moving against each other
- cushion impacts
- keep the layout organised
- show when a tool is missing
- fit the case without buckling
- allow items to be removed without tearing the foam
The foam must be firm enough to hold the cut outs but not so rigid that it is difficult to shape or damages the equipment.
Flat packaging foam for general protection
Flat packaging foam is a lightweight open cell option for lining boxes, briefcases and cases. It can be cut into pads, dividers and simple inserts.
It is useful when:
- weight needs to stay low
- the case is used for general tools or samples
- cushioning is more important than water resistance
- an economical insert is required
Check the product fire information. Packaging foam is not intended for upholstery.
Replacing convoluted lid cushioning
Convoluted or egg crate packaging foam has a profiled surface and is commonly found in older case lids because the peaks can contact items across slightly different heights. All Foam does not currently list a convoluted packaging sheet for online purchase. If you are replacing an existing profiled lid, measure the maximum foam depth, the clearance above the stored items and the amount of movement that needs controlling. A current flat packaging foam, shaped insert or separate cushioning pad may provide a more practical replacement depending on the case.
Use it for:
- lid foam
- light clamping pressure
- separating stacked items
- reducing movement above an insert
The stated thickness includes the profile. Consider the compressed height when planning the case.
Closed cell polyethylene for cleanable inserts
Closed cell foam sheets such as the current AFP30 and AFP45 polyethylene grades are more rigid and absorb far less water than open cell packaging foam.
They suit:
- tool drawers
- workshop storage
- outdoor cases and cases used in damp conditions
- reusable presentation inserts
- equipment that needs a firmer outline
Closed cell foam can be wiped more easily than open cell foam, but it can also be harder to cut neatly by hand.
Plastazote for coloured and presentation inserts
Plastazote LD33 is commonly available in several colours, but it is no longer part of the current All Foam product range.
Colour can help:
- identify tool groups
- create a visible missing tool contrast
- match a brand or department
- separate case layers
Do not choose by colour alone. Confirm the thickness and grade first.
Antistatic foam for electronics
AS22 antistatic pink packaging foam is intended for packaging electronics and sensitive to static items.
Use an appropriate antistatic grade when the equipment requirement calls for it. Ordinary packaging or upholstery foam should not be assumed to provide electrostatic protection because it is pink, dark or dense.
For valuable electronics, follow the equipment manufacturer’s handling and packaging requirements as well as the foam data sheet.
Ethafoam for impact and spacing
Ethafoam STPE200 is a semi-rigid expanded polyethylene packaging foam available in white and grey. It can be useful for:
- blocking and bracing
- impact protection
- case wall spacing
- layered inserts
- reusable transport packaging
Its semi rigid nature makes it different from soft open cell foam. It is selected where shape retention and impact management are priorities.
Reconstituted foam for heavy equipment
Dense reconstituted foam can support heavier equipment, but it is not always the easiest material for detailed hand cut inserts.
It may suit:
- heavy bases
- industrial pads
- robust separators
- equipment stands
- areas where high density matters more than a clean decorative finish
For precision cut outs, a suitable closed cell sheet may give cleaner edges and easier visual organisation.
Choose the right thickness
Measure:
- internal case width and length
- usable case depth
- height of the tallest item
- lid clearance
- the depth needed beneath each item
A common structure uses a base layer, a cut out layer and lid foam. Do not cut all the way through the bottom layer unless the case itself is intended to support the item.
The foam sheet thickness guide explains how thickness affects cushioning and fit.
Make a layout before cutting
Place the tools on paper or card first. Allow enough foam between each item and around the case edge.
Keep:
- heavier items low and central
- sharp edges away from the case wall
- frequently used tools easy to remove
- handles and grip points accessible
- charging cables and accessories in separate spaces
Take a photograph of the planned layout before moving anything.
How to mark the cut outs
Use a light removable marker or a paper template. Trace the tool without pressing it deeply into the foam.
For symmetrical items, mark orientation clearly. For layered inserts, number the layers and note which side faces up.
Do not use a marker that transfers permanently to valuable equipment or reacts with the foam.
Cutting open cell foam
For soft packaging foam, a long sharp blade or electric carving knife can produce a cleaner cut than short repeated strokes.
Use a stable work surface and keep hands clear of the cutting path. Cut in stages rather than forcing the full depth in one pass.
The home foam cutting guide explains tools and common mistakes.
Cutting closed cell foam
Closed cell foam needs a very sharp blade and controlled cuts. A metal straight edge can guide straight lines, but curved tool outlines take patience.
For professional presentation or complex repeated inserts, machine cutting may be more suitable than hand work.
Fixed or loose fit?
A separately selected fixing system can hold a sheet in a drawer or case, but permanent bonding reduces the ability to reposition or replace the insert.
Consider permanent fixing when:
- the case lining is permanent
- the surface is clean and suitable
- the sheet must not slide
Choose a loose fit when:
- the insert may be changed
- the case is hired or reused
- the base material is unsuitable for adhesive
- several removable layers are required
Test the fit before removing the release liner.
Allow for ventilation and contamination
Foam can trap dust, oil and moisture around tools. Clean and dry equipment before storage. Do not seal wet tools into a closed cell insert.
For chemicals, fuels, oils or unusual industrial environments, confirm material compatibility. A general foam guide cannot guarantee resistance to every substance.
Build inserts in layers
Layered inserts are easier to plan than cutting one very thick block. A solid base layer protects the case floor, while the upper layer contains the shaped cut outs. A separate lid layer can hold items gently in place.
Dry fit every layer before bonding. Mark the orientation so a cut layer is not accidentally installed upside down or back to front.
Make tools easy to remove
A precise outline can hold a tool securely but leave no place for fingers. Add a small finger notch at the handle or another safe grip point.
Do not make notches so large that the item moves during transport. For sharp or delicate tools, choose a removal point that does not force the user to touch the blade, probe or fragile component.
Keep a record of the insert design
Photograph the completed layout and keep the paper template. When a tool changes or the foam wears, the record makes replacement easier and helps other users return items to the correct position.
Planning a practical foam insert
For general lightweight case cushioning, start with flat packaging foam. For firm toolbox and drawer inserts, compare the current AFP30 and AFP45 closed-cell sheet options. Use AS22 anti static foam for relevant electronics and Ethafoam for semi rigid impact protection. If an existing case uses convoluted lid foam, treat that as a replacement problem and measure the available lid depth before choosing a current alternative.
Measure the case depth, plan the layout and keep enough material beneath and around each item. View the All Foam foam sheet range and technical data before selecting a grade.
