Foam packaging inserts · runs from 20 units

Custom foam packaging inserts, cut to your product.

Custom foam inserts for the cardboard box your product ships or sells in, designed in-house and cut in our Southern California shop.

Get a packaging quoteSee how it works
20 unitsCustom runs start here
~2 weeksTo your first sample
No CADStart with a photo or dimensions
SoCalDesigned and cut in-house
Sold at
As seen in
Cardboard boxes

The box your customer opens.

A foam insert cut to your product holds it in place inside the box.

  • Shipping boxes
  • Retail and presentation boxes
  • Sample and sales kits
  • Kits with several parts
Our shop

Designed and cut in our shop.

Our team designs the foam in-house, and we cut it on our own machines in Southern California.

  • Die press
  • CNC mill
  • CNC knife cutter
  • Two CO2 lasers
  • Band saw
  • Industrial glue machines
  • UV printing for logos and artwork on cases
How it works

From your product to a finished insert.

Custom foam inserts for cardboard boxes, designed in-house and cut in Southern California.

  1. Tell us about your product and box
    Step 1

    Tell us about your product and box

    Share a photo or dimensions of your product, the inside dimensions of your box and how many inserts you need. No CAD file needed.

  2. We design the insert
    Step 2

    We design the insert

    Our team designs the foam around your product. Ask about adding a laser-engraved logo.

  3. Approve your sample
    Step 3

    Approve your sample

    Your first sample arrives in about 2 weeks. Check the fit, ask for changes, then sign off.

  4. We cut your run
    Step 4

    We cut your run

    Runs start at 20 units. We cut every insert in our Southern California shop to the approved sample.

Recent builds

Foam cut to fit, one product at a time.

Start your build
Tool kit insert
Tool kit insert
Multi-pocket insert
Multi-pocket insert
Ammo insert
Ammo insert
Camera insert
Camera insert
Equipment inserts
Equipment inserts
In our shop
In our shop
How many cases per order?

A real person replies within 1 business day.

Rather talk? wholesale@evergreencases.com (714) 449-7960 M–F, 8am–4pm PT
More foam services

Explore our foam services.

Custom foam insertsFor our Seahorse cases, your cases or your boxes. Foam for Pelican, SKB and NanukCustom inserts for the cases you already own. Tool control foamFoam for tool kits, cut to the shape of your tools. Foam fabricationOur CNC, laser, die press, gluing and UV printing. Foam materialsWZ, Synergy and T30 cross-linked foam. Branded Seahorse casesThe case and the insert together, with your logo UV-printed.
FAQ

Questions, answered.

Something else on your mind? Ask in the form or email wholesale@evergreencases.com.

What is the minimum order?

Custom runs start at 20 units, and we are set up for bulk orders. Need fewer for a prototype or a test? Ask. We can sometimes do smaller runs.

How fast can I get a sample?

Your first sample usually arrives in about 2 weeks. We confirm the schedule for the full order with your quote.

Do I need a CAD file?

No. A photo or the dimensions of what goes inside is enough. Our team designs the foam for you.

Where is the foam cut?

In our own shop in Southern California. Our team designs the foam in-house, and we cut, glue, laser-engrave and UV-print in our shop.

Can you make foam inserts for cardboard boxes?

Yes. Send us the inside dimensions of your box and what goes inside, and our team designs the insert.

Can you glue layers of foam?

Yes. We glue foam in-house with industrial glue machines. Ask us about layered inserts for your product.

Can you engrave our logo into the foam?

Yes. We laser-engrave logos into the foam.

Custom foam quote

Ready when you are.

Custom runs start at 20 units. Need fewer? Ask about a smaller run. A real person replies within 1 business day.

Get a quote