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Foam Packaging

Custom Foam Inserts & Dunnage

Ameripak designs and manufactures custom foam packaging and foam inserts for a wide range of applications— foam trays, end caps, medical device foam, and other dunnage solutions. Foam can be custom-made to any size and thickness.

Our in-house design department works directly with you to find the best material for the job, from Polyethylene (PE) and Crosslinked Polyethylene (XLPE) to Polyurethane (PU), Expanded Polypropylene (EPP), and specialty options like Zotefoam. PSA (pressure-sensitive adhesive) can be applied to foam backings to adhere to outer packaging.

 
 
 
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Material Types Available:

Material Foam Type Key Characteristics Best For
Polyurethane (PU) Open-cell Soft, conforming, strong vibration dampening; absorbs moisture over time Cushioning delicate/irregular parts, short-term protection
Polyethylene (PE) Closed-cell Moisture- and chemical-resistant, low cost, most versatile general-purpose foam Everyday cushioning, case inserts, high-volume applications
High Density Polyethylene (HDPE) Closed-cell Firmer, more rigid than standard PE Structural support, heavier loads
Crosslinked Polyethylene (XLPE) Closed-cell Finer, denser cell structure than PE; higher temperature resistance; tighter tolerances Medical device packaging, Mil-Spec documentation requirements
Expanded Polypropylene (EPP) Closed-cell Excellent strength-to-weight ratio, holds up to repeated impacts Returnable/reusable dunnage, closed-loop programs
Laminated Polyethylene (Lam PE) Closed-cell, multi-layer PE sheets bonded together to build custom thickness or combine densities Custom-thickness inserts, multi-density trays
Polyester Foam Open-cell Soft, breathable cushioning Padding where airflow matters
Zotefoam Closed-cell, nitrogen-expanded Very fine, uniform cell structure; cleanroom-compatible Medical/pharma, cleanroom-grade packaging