- Material: XPE foam, IXPE foam
- Expansion ratio: 25 times (40 kg/m³), 30 times (33 kg/m³)
- Thickness: single layer 1–12 mm, multi-layer 200 mm or less (thermal composite)
- Colour: black and gray (colour can be customized)
- Flame retardant grade: UL94 HF-1
Customization
Made to order: density, thickness, colour and shape to your drawing. Die-cutting, CNC routing, lamination to film or fabric, slitting and adhesive coating all run in-house, so the part we quote is a finished part, not just a sheet. How a custom part is cut and routed explains what to send with the drawing.
Regular material: MOQ 1,000 m², lead time 15–20 days from order confirmation. Custom parts are quoted from the drawing. A4 samples are free, shipping included.
Metal parts arrive damaged in two ways: they bend, or they scratch. Both usually happen because parts were free to move against each other inside the carton. Bofeng die-cuts hardware packaging foam inserts from XPE and IXPE foam, with compartments that hold each item separately, so finished surfaces and machined faces reach the customer exactly as they left the line.
Features
- Part separation – compartments that stop metal parts striking and scratching one another in transit.
- Compressive strength – closed-cell foam carries the weight of dense parts without collapsing under them.
- Single or laminated build – 1–12 mm as a single layer, or thermally laminated up to 200 mm for deeper cushioning.
- Moisture resistant – absorbs very little water, so parts are never held against damp.
- Cut to shape – die-cut to your component outline, including recesses for protruding fittings.
- Colour options – black and gray as standard, with other colours on request.
Applications
- Tools and hand tools – organised trays for workshop and service cases.
- Fittings and fasteners – kits held in counted positions, so nothing is missing on site.
- Machined and cast parts – protection for machined faces, threads and bores.
- Automotive components – brackets, trim clips and small assemblies.
- Household hardware – lamps, sanitary ware and flat-pack fittings.
Specifications for hardware packaging foam
A hardware foam insert is a die-cut part, so the sheet has to hold a cavity, keep its thickness and cut cleanly.
| Foam | Expansion | Apparent density | Single-layer thickness | Why this grade |
|---|---|---|---|---|
| XPE | 10–20× | 50–100 kg/m³ | 3–15 mm (heat-bonded 15–200 mm) | The standard insert grade, because machined faces and sharp edges must not be marked, so the foam has to conform without being hard. The 50–100 kg/m³ band holds a die-cut cavity and does not fatigue in a repeating transit cycle. |
| IXPE | 20–30× | 33.3–50 kg/m³ | 0.1–15 mm | Fine-cell sheet for the lid liner and for thin interleaving between parts, where a firmer sheet would not close. |
Base material specifications are on the XPE, IXPE and IXPP material pages; finished products are on the XPE foam and IXPE foam pages. Tell us the load, the space available and the service temperature and we will confirm the grade against your drawing.
Why Choose Bofeng Foam
- Single layer 1–12 mm, thermally laminated up to 200 mm where needed.
- Flame-retardant grade available – UL94 HF-1.
- Black and gray as standard, other colours on request.
- Die-cut to your component outline from a drawing or a physical sample.
- Samples and specification sheets available before production.
Designing an insert around a heavy part — where the load sits, and how much foam has to remain underneath it — is covered in our custom foam insert design guide.
Conclusion & Inquiry
Packaging foam covers the wider range of custom inserts and trays, and tool box foam inserts applies the same cut-to-outline approach to complete tool kits. Contact us with your part list or a sample and we will quote a cut layout.
