CAPABILITIES / APPLICATIONS / CUSHIONING & IMPACT

Cushioning & Impact Protection

Absorb impact, distribute load, and protect whatever's inside. Open-cell and cross-linked foams tuned to your drop profile, weight, and reuse requirement.

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Recommended Materials

Impact-tuned foams

From single-use packaging foam to repeatable defense-grade impact pads. We’ll match the foam’s G-curve to your drop profile.

Cross-linked PE (Volara)

Repeatable cushioning · clean cut · case insert standard

Plastazote LD

Light-density closed-cell PE · contoured CNC routing · medical positioning

PORON XRD

Extreme impact protection · slim profile · reusable hundreds of cycles

EVA Foam

Mid-density · anti-static grades · sports & consumer goods

Polyethylene EPE

Single-use shipping foam · cost-optimized · disposable packaging

Anti-Static EPE

ESD-safe · electronics packaging · pink/black grades

Case Studies

Drop tests, deformations, and field life

Consumer Electronics

Tablet retail packaging insert

ProblemBrand was losing 4–6% of tablet shipments to drop damage during last-mile carrier transit. Existing pulp tray failed ISTA 3A.

SolutionCNC-routed Volara cross-linked PE inserts with custom geometry per tablet body, tuned through 3 drop-test iterations in 9 business days.

MaterialsVolara Type S 4# · CNC routed · matte black face

✓ISTA 3A passed · returns −80%

Defense / Optics

Night-vision optic transport cradle

ProblemExisting cradle foam compressed permanently after 2–3 years of field storage, leaving the optic loose in its case and out of zero on deployment.

SolutionPlastazote LD45 cradle CNC-routed to optic geometry with PORON XRD impact pads at strike points. Spec validated against MIL-STD-810 transit drop.

MaterialsPlastazote LD45 · PORON XRD 12mm · PSA bonded

✓10-year storage validated · zero set

Related Capabilities

How we build cushioning parts

→CNC Routing3-axis routing of thick foam blocks for contoured cradles and inserts. →Flatbed Die CuttingMid-volume conversion of sheet stock for pads and dunnage. →Adhesive LaminationMulti-density stacks: hard outer + soft inner for tuned G-curves. →Custom ThermoformingHeat-formed cradles for deep contours and one-piece cavities.

Industries Served

Where impact protection ships

Consumer ElectronicsMedical DevicesDefenseAerospaceSports EquipmentIndustrial ToolsLogistics & Packaging

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Have a Cushioning & Impact Protection project?

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