Foam Fabrication
/Foam-Fabrication.aspx?width=200&height=130) Cost-effective solutions for all your foam fabrication needs….since 1972, customers worldwide have turned to Custom Pack, Inc. for the highest quality foam fabrication in the marketplace. One of the main reasons for our success is our unwavering commitment to complete customer satisfaction. Over the years we have earned the reputation for reliability, responsibility and innovation. Customer satisfaction has always been…and always will be our main focus. From your initial contact to after-the-sale follow-up, our people are committed to providing you with prompt cost-effective solutions to your specific needs, on-time delivery, and everything in-between. Every project provides us a new opportunity to build a relationship, and over 30 years of experience serving various communities has taught us that building long-standing and mutually beneficial relationships is a top priority.
At Custom Pack, we have the expertise to not only meet your needs today, but are prepared to help you meet your development goals of tomorrow. Our 36,000 square foot facility in Exton, Pennsylvania, offers one-stop design and fabrication convenience all under one roof. This location provides our customers with on-site engineering, hands-on technical support and help with material selection, and state-of-the-art equipment as well as fabricating and warehousing capabilities. Centrally located, we are convenient to some of the major industry suppliers of a variety of foams.
Specifications · Custom Foam Fabrication Features · Facility · Facility List · Quality & Beyond · Services
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Foam Types
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Crosslinked Polyethylene Foam
Expanded Polystyrene Foam
Polyethylene Foam
Polyurethane Foam
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Custom Foam Design
Custom Pack is totally integrated. We have the design engineering experience, material knowledge, and state-of-the-art equipment to cost-effectively handle the most demanding projects. Our R&D staff is continually monitoring new equipment and manufacturing techniques to meet the ever increasing demands of our industry. Throughout the years, we have expanded and improved our manufacturing and design engineering capabilities. It seems that no matter what the requirement, our in-house equipment accommodates a wide range of production processes, including sawing, sheeting, contouring, water jet cutting and die cutting, pressure forming, convoluting, molding, laminating, and hot wiring. Based on accumulated knowledge, experience, and the customer’s specific requirements, we are able to recommend a particular type and density of foam to best suit their demand. CAD-CAM drawings incorporate the design and selected foam to create the perfect package for the particular product need. Today, CPI's foam fabricating services are second to none.
Prototyping
Upon approval by the customer, the proposed design is taken to the next level. From the CAD-CAM drawings, a steel-ruled cutting die or mold, whichever the requirement, will be produced and a sample part provided to the customer from the foam of choice to ensure fit and functionality prior to production.
Selection of Materials
It is important that the foam type and density be suited to the particular application. Custom Pack offers a variety of foam types in a choice of colors, as follows:
Polyurethane Foam
Polyurethane is an “open cell” foam which offers excellent resilience and durability. It is easily fabricated for many general industrial and commercial applications. Urethane foam is readily available in a wide range of densities. This, combined with its cushioning, moisture absorption, and sound dampening capabilities makes polyurethane an extremely versatile foam choice.
A few examples of polyurethane foam applications include: athletic equipment, filtration, insulation, gasketing, and special packaging for the electronics, appliance, cosmetic, and instrumentation markets. Also, with a fire-retardant additive, it is a natural for the children’s toy market.
Expanded Polystyrene Foam
Expanded polystyrene foam, made from small “beads”, can be custom molded to specific sizes and shapes. It can also be made into “boards” of different lengths and thicknesses used in the fabrication of smaller sized parts. However, custom molding is generally reserved for larger quantities with more demand for precision.
Polystyrene foam offers high compressive strength in a full range of densities. Its ease of fabrication makes it ideal for platforms, displays, inner package support, cushioning and corner pads.
The molding capabilities are limitless, and some current applications include platforms, trays, and packaging in the fields of electronics, appliances, photography, toys, medical devices, machine parts, and office equipment.
Polyethylene Foam
Polyethylene is a “closed cell” foam featuring superb durability, shock absorption and abrasion resistance characteristics. In addition, it is odorless, buoyant, and does not absorb liquids.
These characteristics make it particularly effective for recreational/athletic equipment, as well as water sport and flotation equipment. Being resistant to most solvents and chemicals gives it a natural advantage in agricultural, construction, and industrial applications.
The fact that polyethylene foam lends itself to cutting and shaping, and will not fracture under stress, has given it wide acceptance in nearly every concept of protective packaging.
Crosslinked Polyethylene Foam
This is a closed cell foam available in rolls and planks. It can be thermoformed, heat pressed die cut, and fabricated into a variety of shapes. This foam is compliant with various medical applications.
Need it Assembled????
Again….big or small, at Custom Pack we do it all – start to finish. If your need is for the foam to be assembled, either individually or with components into a carton, we can accommodate you. We are a full service organization.
Equipment & Systems Enhancement
Our R&D staff is continually monitoring new equipment and manufacturing techniques to meet the ever increasing demands of our industry.
Industries Served
CPI serves, but is not limited to, the following industries: Cosmetics, Electronics, Pharmaceutical, Medical/Healthcare, Food, Automotive, Toy, and Consumer. Our “White Room” environment accessible at CPI allows us the opportunity to work in a sterile environment required by our major medical accounts and conform to our ISO 9001:2008 Certification.
ISO 9001:2008 Certification and Beyond
Custom Pack, Inc. continues to maintain Quality Management System standards for “Design and Manufacturing of Packaging.” ISO 9001:2008 Certification ensures that our processes are consistent every time, from design to fabrication and beginning to end. It is our goal to produce a quality part first time, every time, to meet our customers’ requirements.
At Custom Pack, we understand the importance of adhering to a quality management system, not only in our own operation, but on behalf of our customers as well. Quality Assurance is not just a “buzz word”. Process control is performed at every stage of the manufacturing process to assure that customers’ exact specifications are met, whether it be a specified material, required process documentation, production environment, packaging requirement, etc.
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Production & Warehousing Capabilities
Centrally located in Exton, Pennsylvania, we offer the convenience of experienced customer service representatives, design, fabrication, assembly, and warehousing capabilities all under one roof. Our 36,000 square foot facility contains a 3,000 square foot White Room for specific clean room applications. State-of-the-art computerized equipment is programmed to operate efficiently within a specified set of guidelines, and qualified personnel are on duty at all times for monitoring. The abundant warehouse space allows the ability to assemble and package prior to shipment, as well as accommodating just-in-time shipments and deliveries of custom products.
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Building
36,000 Square Feet of Offices, Manufacturing, and Warehouse Space
Manufacturing Equipment
State-of-the-art die cutters, molding machines, and high-speed saws are conveniently located under one roof for convenience. Equipment is maintained and serviced to schedule to keep it operating at peak performance.
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Custom Pack, Inc. continues to maintain Quality Management System standards for “Design and Manufacturing of Packaging.” ISO 9001:2008 Certification ensures that our processes are consistent every time, from design to fabrication and beginning to end. It is our goal to produce a quality part first time, every time, to meet our customers’ requirements.
At Custom Pack, we understand the importance of adhering to a quality management system, not only in our own operation, but on behalf of our customers as well. Quality Assurance is not just a “buzz word”. Process control is performed at every stage of the manufacturing process to assure that customers’ exact specifications are met, whether it be a specified material, required process documentation, production environment, etc.
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Industries Served
CPI serves, but is not limited to, the following industries: Cosmetics, Electronics, Pharmaceutical, Medical/Healthcare, Food, Automotive, Toy, and Consumer. Our “White Room” environment accessible at CPI allows us the opportunity to work in a sterile environment required by our major medical suppliers.
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Custom Foam Diecuts
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Polyurethane Foam
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Polystyrene Foam
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Polyethylene Foam
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Crosslinked
Polyethylene Foam
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Custom Diecutting
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Steel Ruled
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Precision Sawcutting
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Consumer Foam
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Custom Foam and
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Foam Endcap Design
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Medical Foam
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Shipping
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Package Stability
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White Room
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Facility,
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Warehouse and
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Quality Assurance
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Custom Design
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