- Material: XPE foam, IXPE foam
- Expansion ratio: 25 times (40 kg/m³), 30 times (33 kg/m³)
- Thickness: surface layer 2–5 mm, bottom layer 20–40 mm (thickness can be customized)
- Colour: black + red, black + blue (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.
A toolbox is only organised if every tool has one place to go. Tool box foam inserts are cut to the outline of each item, so the layout holds itself together and a missing tool is obvious the moment the lid opens. Bofeng builds these inserts as a two-layer construction: a thin coloured surface layer over a thicker base, which gives the cut-outs a clean edge and the tools a firm seat.
Features
- Two-layer build – a thin coloured surface layer over a 20–40 mm base, so cut-outs read clearly and tools drop into place.
- Shaped tool cavities – die-cut to each tool outline, so nothing shifts when the box is carried, tipped or dropped.
- Impact absorption – the thicker base takes the shock of a knocked or dropped case before it reaches the tools.
- Wear resistant – closed-cell foam holds its shape through years of daily use.
- Easy to clean – the smooth, non-absorbent surface wipes clean of oil and swarf.
- Colour coded – black with a red or blue surface layer as standard, so a gap in the layout stands out at a glance.
Applications
- Automotive workshops – sockets, spanners and diagnostic kit held in numbered positions.
- Machine shops – gauges and cutting tools protected so calibration survives transport.
- Electrical and plumbing service – hand tools and meters organised in portable cases.
- Field service and maintenance – cases where a missing tool has to be spotted immediately.
- Photography and instruments – cameras, lenses and precision equipment in fitted cases.
Specifications for tool box packaging foam
A tool box 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 the cavity walls have to hold a socket or a spanner in place through repeated opening and closing. 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
- Two-layer construction: thin surface layer over a 20–40 mm base.
- Flame-retardant grade available – UL94 HF-1.
- Black + red or black + blue as standard, further combinations on request.
- Die-cut to your tool layout from a drawing or a photographed tray.
- Samples and specification sheets available before production.
Where die-cutting stops and CNC routing starts, and what makes a routed cavity expensive, is covered in our die-cutting and CNC routing guide.
Conclusion & Inquiry
A well-cut tray is what turns a box of tools into a controlled kit. Packaging foam covers the wider range of inserts and trays, and shadow foam applies the same idea as a wall or drawer board. Contact us with your tool list or a photograph of the tray and we will quote a cut layout.
