Making the proper selection for die cut foam packaging supplier
The foam supplier must have the capabilities and resources to cut and/or form foam products to serve an infinite variety of needs. Since there is a wide range of foam materials, it is important to choose which is the most appropriate in providing the level of protection required by the product. Different types of foam have inherent characteristic like high shock absorption or thermal insulation and it helps if the foam supplier will work together with the customer in determining the right kind of foam for die cut foam packaging. There must also be the capacity to laminate different materials to create high performance composites for specific applications. There are companies that have the capability for die cutting, water jet cutting or laser cutting including the post-treatment processes to ensure the strength and durability of foam packaging.
How the die cutting of foam works
A die cutter operates like a large-scale cookie cutter that cuts exact shapes out of foam. Dies which are also known as plates have thin finely serrated blades to create a cutting pattern. Sheets of foam are spread over the plates and are compressed by pressure. The foam is pressed down over the dies, cut into specific shapes and released, creating a form that exactly matches the design required for die cut foam packaging. The tables used in the creation of die cut foam packaging typically measure 76” by 32” so that a large number of forms can be produced quickly and economically.
When there is a relatively large number of orders for foam packaging, dies can be utilized to produce bulk quantities. Water jet cutting which is a method of cutting foam for packaging is effective for making hundreds per item but the die cutters are effective at tens of thousands in approximately the same amount of time invested. Die cutting becomes a more economical choice when there is a requirement for mass production of die cut foam packaging for toys or novelty items.
Die cut foam packaging provides a precise fit that will reduce any potential for the product to move during transit or rough handling. Usually a product has different components and if all these components can be fit in a single die cut foam packaging, it will reduce the costs involved in packaging the product. Since foam is extremely lightweight, it keeps the shipping and storage costs to a minimum and the end-users will not be impacted by the high cost of packaging and shipping.