Mission-critical foam fitments engineered in Bengaluru 560066 for avionics LRUs, turbine sensors, UAV payloads and MRO cases. AS9100-aligned processes, ATA 300 / MIL-STD-810 cushioning references, and CAD-driven CNC machining — trusted by aerospace OEMs and Tier-1/Tier-2 suppliers across the Bengaluru, Hyderabad and Chennai corridor.
Aerospace cargo sees more environmental punishment than almost any other shipment — multi-modal handling, pressure swings at altitude, sub-zero hold temperatures, monsoon humidity on Indian highways, and salt-fog on coastal MRO returns. A foam cradle that looks fine in a workshop can shed fibre into a connector, take a permanent compression set, or simply stop fitting after three trips.
We design every aerospace fitment around six engineering pillars — calculated against the fragility curve of the protected component, not against generic "soft foam" rules of thumb.
Cushion thickness sized to drop-height and component fragility (G-level) curves.
Closed-cell XLPE retains structure across –40 °C to +70 °C and pressure swings.
Skin-finished, non-shedding foams keep loose fibre out of LRU connectors and bays.
Hydrophobic cells survive monsoon transit and coastal storage without degradation.
Pink anti-static EPE and conductive PU options for sensitive electronic LRUs.
Tool-controlled cavities so MRO returns ship back in the same protective cradle.
Drop height, G-levels, transit mode, MIL-STD-810H and ATA 300 Cat I/II references.
STEP / IGES / DXF / DWG under NDA — or 3D-scan from a physical sample.
XLPE density, EVA, PU ester or anti-static EPE chosen against the fragility curve.
CNC-machined sample, fit-check on the LRU, in-house drop and compression validation.
Customer FAI sign-off, density and dimensional report, optional third-party test.
Batch CNC, labelling pockets, serialised cradles for traceability and MRO returns.
| Material & density | Compression set | Typical aerospace use |
|---|---|---|
| XLPE 30 kg/m³ | Low (~5%) | Light avionics LRUs, instrument panels |
| XLPE 60–90 kg/m³ | Low–Medium (~8%) | Standard avionics & sensor cradles |
| XLPE 200 kg/m³ | Very low (~3%) | Turbine blades, heavy probe cases |
| EVA (medium density) | Low (~10%) | Tool control, calibration kit inserts |
| PU ester (open cell) | Recovers fully | Optical & EO/IR payload cradles |
| Anti-static pink PE | Low (~12%) | ESD-sensitive avionics PCBs & LRUs |
Compression set values are indicative for the densities we typically supply; final values depend on test method (e.g. ASTM D3575) and customer-specified conditioning.
NestPack designs and tests aerospace foam fitments aligned to the references below. We do not claim independent certification — final certification is the responsibility of the container OEM or the customer's quality system.
Reusable shipping container categories — drives cradle reuse cycles.
Shock, vibration, drop, humidity & temperature test references.
DoD packaging preservation methods — barrier and cushioning levels.
Environmental conditions for avionics — informs storage cushioning.
Lithium battery transport cushioning for UAV and avionics shipments.
Heat-treated wood crating that pairs with our foam interiors for export.
Tier-1 supplier reported in-transit rework on a navigation LRU after multi-modal shipments.
Two-piece XLPE 60 kg/m³ cradle with tool-controlled cavity, lift cut-outs and ESD-foam contact face inside a Pelican-style hard case.
Reported 40% reduction in transit rework and reuse across 12+ MRO cycles.
Heavy single-blade returns were arriving with edge-contact damage in returnable wooden crates.
CNC-machined XLPE 200 kg/m³ cradle conforming to the blade aerofoil, paired with an ISPM-15 export crate.
Zero edge-damage reports across the first production batch of 50 units.
MRO bay needed FOD-proof tool layout for a portable flight-line kit.
Two-colour shadow board in EVA — black base, hi-vis orange contrast layer — with serialised pockets for each tool.
Tool accountability checked in under 30 seconds per shift change.
Yes. We design and manufacture foam cradles intended for use inside ATA 300 Cat I, II and III shipping containers. We align our cushioning calculations to the drop-height and reuse cycles defined in the spec, but ATA 300 certification of the finished container is performed by the container OEM.
Prototype samples ship in 5–8 working days from our Bengaluru 560066 facility once CAD or a physical sample is approved. Production batches typically run in 2–4 weeks depending on density, finish and quantity.
Yes. We accept STEP, IGES, DXF, DWG and PDF drawings under NDA. Our design team converts the part envelope into a tool-controlled cavity with capture features, lift cut-outs and labelling pockets before CNC machining the foam.
Yes. We supply foam inserts that pair with ISPM-15 compliant wooden crates and aluminium hard cases. We can deliver the complete kit — outer crate, foam interior and desiccant — palletised and ready for international freight from Bengaluru.
Our default XLPE and EVA grades are chemically stable, low-residue and suitable for avionics handling. For optical, satellite or cleanroom assemblies we offer specially selected low-outgassing and anti-static grades on request.
Send your LRU drawings, CAD or a sample — we'll engineer the foam cradle from our Bengaluru 560066 facility.