Custom Foam Inserts • India

Custom Foam Inserts, Made in India

NestPack builds custom foam inserts for hard cases, corrugated boxes, ATA flight cases and wooden crates across every major industrial hub in India. Our team CAD-designs each cavity from your STEP, DXF or physical sample, selects the right foam grade (EPE, XLPE, EVA, PU or anti-static), and produces the insert on CNC routers, waterjet cutters and die-cutting presses. Whether you need one prototype for an aerospace LRU or 10,000 monthly units for medical device packaging, we deliver parts that fit like moulded plastic — but at foam-tooling cost. Prototype samples ship in 5–8 working days from our Bengaluru 560066 facility, with pan-India logistics for Chennai, Hyderabad, Pune, Mumbai and Delhi NCR.

+91 96863 88696

Made in India ISO-grade QC 35+ cities served Prototype in 5 days

What we offer

CAD-First Design

STEP / DXF / IGES to production-ready foam cavity in under 48 hours.

Every Foam Grade

EPE, XLPE, EVA, PU pluck, anti-static and cross-linked polyethylene.

CNC + Die Cut

3-axis CNC routers up to 2500×1500 mm plus rotary die-cutting presses.

Prototype in 5 Days

First article samples in 5–8 working days from our Bengaluru unit.

Pan-India Delivery

35+ industrial cities served with dedicated freight partners.

Volume Ready

10 to 10,000+ units per month with consistent density and finish.

Specifications

Material	Density	Best For
EPE Foam	18–35 kg/m³	Light electronics, gifting, medical trays
XLPE Foam	25–90 kg/m³	Rugged tool cases, defence, aerospace
EVA Foam	60–200 kg/m³	Premium presentation, dense inserts
PU / Pluck Foam	25–35 kg/m³	Field-serviceable cases, on-site cavities
Anti-Static EPE	25–35 kg/m³	PCBs, sensors, ESD-sensitive assemblies

Industries we serve

Materials & related products

Our process

01
CAD or Sample
Send STEP / DXF or a physical sample under NDA.
02
Design Review
We propose cavity layout, foam grade and finish.
03
Prototype
First article shipped in 5–8 working days for approval.
04
Production
Volume manufacturing with QC on every batch.

Delivering across India

Bengaluru dispatch with 2–4 day transit to every major industrial hub.

Frequently asked questions

What is the minimum order for custom foam inserts?

There is no MOQ for prototypes — we build one-offs. Production runs typically start from 25 pieces per SKU.

How fast can I get a sample?

5–8 working days from CAD or physical-sample approval. Rush prototypes in 72 hours are possible on request.

Which foam should I pick for my product?

EPE for light electronics and gifting, XLPE for rugged and heavy tools, EVA for premium presentation, PU pluck for field-serviceable cases, anti-static for PCBs and sensors.

Do you deliver outside Bengaluru?

Yes — we ship to 35+ cities including Chennai, Hyderabad, Pune, Mumbai, Delhi NCR, Ahmedabad and Coimbatore with 2–4 day transit.

Can you match Pelican, Nanuk or Explorer case interiors?

Yes. We regularly design drop-in replacement inserts for Pelican, Nanuk, Explorer, SKB and B&W cases.