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Polyurethane (PU) Foam Insert

Key Features:

Custom molded polyurethane (PU) foam inserts are the perfect choice for protecting your products against damage due to its high shock absorbent characteristic while creating a luxury look and feel. In addition, PU foam is an excellent choice for its lightweight and compressible (easy to store) nature.

  • Lightweight and compressible for easy storage
  • Shock absorbent material
  • Custom-molded to your product


PU, short for polyurethane, is a kind of open-cell foam material that is lightweight and more compressible than other foam alternatives, making it very versatile in many packaging applications. In addition, due to its soft characteristic, PU foam has high shock absorbency, turning this material a standard selection among many industries looking for added protection. Our polyurethane foam inserts are available in a wide range of densities and colors.

Foam Comparison Density (kg/cm³) Hardness Overall Weight Available Colors
Polyurethane Foam (PU) 18 - 45 kg/m³ 38/45/60 Shore C Light Black, White, Grey, Yellow
Polyethylene Foam (EPE) 20 - 120 kg/m³ 30 - 38 Shore C Light Black, White, Pink
Ethylene-Vinyl Acetate Foam (EVA) 33 - 280 kg/m³ 15 - 80 Shore C Heavy Black, White




Foam Fabrication Methods


1. Water Jet Cut

Process of cutting material with a high-pressure jet of water—ideal for producing extremely accurate shapes.

2. Knife/Router Cut

Process of cutting material using a router bit or knife—ideal for prototyping due to its imprecise finish.

3. Die Cut

Process of cutting material using a series of dies—ideal for simple two-dimensional cutouts.

4. Wire Cut

Process of cutting material using a heated metal wire to melt and vaporize foam to create clean, crisp cuts.

5. Laser Cut

Process of cutting material using a high-power laser beam to cut and vaporize foam for smooth edges.

Additional information


Duplex Chipboard, Grey Chipboard Cardboard, SBS C2S, Natural Brown Kraft, White Kraft, Black Kraft, Metallic Paper, Holographic, Textured

Printing Methods

Offset Print, Digital Print, UV Print, Scodix Digital Enhancement


Water-based Inks, Soy/Vegetable Based inks, Fluorescent Color Ink, Oil Based Inks, Pantone, Pantone Metallic


Aqueous Coating, UV Coating, Spot Gloss UV, Soft Touch Coating, Varnish, Lamination, Anti-scratch lamination, Soft touch / Silk Lamination

Addition Options

Hot Foil Stamping, Cold Foil Printing, Blind Embossing, Blind Debossing, Registered Embossing, Combination Embossing, Window Patching


Plastic Handles, Leather Handles, Macramé Handles, Ribbon Handles, Ribbon & Bows, Metal Locks, Magnetic Locks, Child Resistant Locks

Options Details