Custom Foam Inserts Manufacturer in India
NestPack manufactures custom foam inserts and foam trays in EPE, XLPE, EVA, PU and anti-static foam — CNC-cut or die-cut to your product's exact geometry at our Whitefield, Bengaluru 560066 factory. From 10-unit prototype batches to 10,000+ monthly units, supplied to OEMs pan-India.
Choose Your Foam Material
EPE Foam Inserts
Lightweight & anti-static — ideal for electronics and PCB trays.
View
XLPE Foam Inserts
Closed-cell, high-density — aerospace LRUs and rugged cases.
View
EVA Foam Inserts
Premium die-cut presentation — surgical kits and tool control.
View
PU Foam Inserts
Soft polyurethane cushioning, pluck-foam & anti-vibration.
ViewAnti-Static Foam Trays
Pink EPE & black conductive foam for ESD-sensitive ICs.
ViewHard Case Foam Inserts
Pelican-style rugged case foam, pluck & layered.
ViewFoam Grades We Convert
| Material | Density | Typical thickness | Best suited to |
|---|---|---|---|
| EPE | 18–35 kg/m³ | 3–100 mm | Light electronics, gifting, one-way packaging |
| XLPE | 30–200 kg/m³ | 3–50 mm (laminated to 250 mm+) | Transit cradles, avionics LRUs, reusable cases |
| EVA | 60–250 kg/m³ | 2–60 mm (laminated to 200 mm+) | Tool control, calibration kits, presentation cases |
| PU | Soft / flexible grades | Ask for current datasheet | Cushioning, pluck-foam, anti-vibration |
| Anti-static / conductive | ESD-safe EPE & conductive grades | Ask for current datasheet | PCB trays, IC shipping, ESD-sensitive assemblies |
Indicative grades — final density and wall thickness are engineered from your component weight, fragility and drop-height target. Ask us for the current datasheet of any grade.
How Foam Tray Manufacturing Works
- 1. Share your product data
Send STEP / IGES / DXF files, a dimensioned drawing or a physical sample.
- 2. Cavity design & material selection
Our engineers CAD-design the cavity and select the foam grade from component weight, fragility and case type.
- 3. First-article prototype
Prototype samples ship in days — typically 5–8 working days from drawing approval.
- 4. Production & dispatch
CNC or die-cut production in 2–3 weeks, quality-checked and dispatched pan-India.
Want the full engineering detail — machine envelopes, tolerances and CAD file requirements? See our custom foam inserts capability guide.
CNC or Die-Cut Precision
Foam Inserts Engineered for Indian OEMs
- All foam types under one roof — EPE, XLPE, EVA, PU, anti-static
- CAD-driven design from STEP / IGES / DXF or physical sample
- CNC routers up to 2500 × 1500 mm bed with ±0.5 mm tolerance
- Prototype in days, full production in 2–3 weeks
- From 10 units per order to 10,000+ units per month
- Whitefield, Bengaluru 560066 — 35+ cities served pan-India
- Trusted by aerospace, defence, medical & electronics OEMs
Custom Foam Insert FAQs
What drawing formats do you accept for custom foam inserts?
We work from STEP, IGES or DXF files, a dimensioned drawing, or even a physical sample of your product. Our team CAD-designs the cavity, shares it for approval and then cuts the insert on CNC routers or die-cutting presses.
Which foam material is right for my product?
EPE (18–35 kg/m³) suits light electronics and one-way packaging; XLPE (30–200 kg/m³) suits rugged transit cradles and reusable cases; EVA (60–250 kg/m³) suits premium tool control and presentation kits; PU suits soft cushioning and pluck-foam; anti-static grades protect ESD-sensitive PCBs. Send your component weight and fragility and our engineers recommend a grade.
What is your minimum order quantity?
Custom foam inserts start from 10 units per order, scaling to 10,000+ units per month with consistent density and finish. Single prototype samples are also produced for design validation.
How long does a custom foam insert order take?
First-article prototypes ship in days — typically 5–8 working days from drawing approval. Full production runs are typically completed in 2–3 weeks depending on quantity and finishing.
Do you supply foam trays outside Bengaluru?
Yes. Inserts are manufactured at our Whitefield, Bengaluru 560066 factory and dispatched to 35+ industrial cities across India — including Chennai, Hyderabad, Pune, Mumbai, Delhi NCR and Ahmedabad — with dedicated freight partners.
Not sure which grade fits? Call us on +91 96863 88696 or send an enquiry — our packaging engineers reply with a material recommendation, not a brochure.