Top 5 Custom Foam Inserts for EVA Cases Benefits and Applications

When it comes to product protection and presentation, custom EVA cases have become a ideal solution for industries worldwide.  But what truly enhances their functionality is what's inside, the correct foam insert.  At Yisi Packing, we understand that a well designed foam insert can make all the difference in protecting, organizing, and showcasing your products.

In this article, we’ll explore the top 5 custom foam insert types used in EVA cases, their unique benefits, and where they are commonly applied.

1. PU Foam (Polyurethane Foam)

Best for: Lightweight, shock absorbing protection

Industries: Consumer electronics, medical tools, retail packaging

PU foam is soft, flexible, and highly shock absorbent, making it ideal for items that require gentle cushioning.  Its spongy texture allows for a snug fit around irregularly shaped products. It’s also affordable and lightweight, perfect for consumer products like cameras, beauty tools, and medical devices.

Benefits:

• Lightweight and flexible

• Absorbs shock and vibration

• Cost effective for high volume packaging

2. PE Foam (Polyethylene Foam)

Best for: Durable, rigid support and reusable packaging
Industries: Tools, drones, instrumentation, industrial kits

PE foam is firmer than PU foam, offering better structure and durability.  It’s ideal for heavier items or equipment that need to be stored or transported repeatedly.  PE foam inserts also resist moisture and chemicals, which is a major plus for industrial and outdoor applications.

Benefits:

• High durability and impact resistance

• Good for repeated use

• Water and chemical resistant

3. EVA Foam

Best for: Premium protection and branding
Industries: Luxury products, electronics, promotional kits

EVA foam is the same material as the outer shell of your case, offering a cohesive, high quality look and feel.  It’s semi rigid, meaning it holds its shape well while still providing excellent shock absorption.  EVA foam is also great for custom color matching and CNC, excellent for premium product packaging or promotional kits.

Benefits:

• Premium look and feel

• Excellent customization (color, logo, shape)

• Long lasting structural integrity

4. Die Cut Foam Inserts

Best for: Custom fit protection for unique or complex products
Industries: Medical devices, instrumentation, collectibles

Die cut foam can be created from PU, PE, or EVA and is precision cut to fit your product’s exact shape.  This ensures maximum protection and eliminates shifting during transit. It's perfect for high value or sensitive products that demand a tailored fit.

Benefits:

• Perfectly fits any shape

• Offers maximum protection

• Enhances presentation and unboxing experience

5. Pick and Pluck Foam (DIY Foam)

Best for: Low volume or adjustable storage
Industries: Hobbyists, toolkits, DIY, samples

Pick and pluck foam allows users to remove foam blocks manually to fit their items.  While not suitable for high end or mass market products, it’s great for prototypes, sample kits, or adjustable storage cases where product sizes may vary.

Benefits:

• Flexible layout without tooling

• Cost effective for small runs

• Easy to customize on the spot

Choosing the Right Foam Insert

Each type of foam insert offers specific advantages depending on your product's size, weight, fragility, and usage.  At Yisi Packing, we work with clients to develop custom EVA case solutions with the perfect foam insert to ensure functionality, durability, and an enhanced user experience.

Need help designing your next custom EVA case with foam inserts?

👉 Contact us today for a free consultation or sample!