When shipping something very delicate that needs special care and packaging, you may not want to rely on foam peanuts or even bubble wrap to keep that item safe. These packaging materials may not actually protect all the delicate details of items like intricate vases, handguns, machine parts, and so on. A better choice for many such items are foam inserts, which can be cut and molded to a part or piece in particular. Note a few quick tips on choosing foam for case inserts for shipping and packaging.

1. Polyethylene foam

Polyethylene foam is very lightweight so it's good for avoiding added shipping charges when packaging something very large. It's also very durable, so you can use it against heavier objects that might cut into lighter foam. The material is also nonabrasive, making it a good choice for delicate objects. It doesn't hold dust, so for handguns and machinery and anything that might be damaged by dust, it's usually the best choice. Polyethylene also avoids rot, mold, and mildew, good for anything that might cause dampness or hold moisture.

2. Polyurethane foam

Polyurethane foam is very lightweight and has excellent cushioning properties for delicate objects. It's what is called an open-cell foam, meaning the air cushions or pockets in the foam are quite large, making it more shock absorbent without being brittle and abrasive. Choose the density of foam according to the protection needed; for sturdier objects, you might choose a very dense polyurethane, but this can cause abrasion against items like glass and porcelain. Opt for a lighter, less dense polyurethane for these items. Polyurethane foam is usually very affordable, so it can be good for large volumes of shipping.

3. Custom inserts versus foam sheets

When choosing foam inserts, should you opt for custom inserts or foam sheets? If you ship the same items repeatedly, custom inserts can allow you to keep them safe during shipment. However, many types of foam inserts are easy to fabricate with the right cutting tools, and this can allow you to create custom inserts on your own. If your shipments vary in size and dimensions, such as when shipping various prototypes, you might opt for plain foam sheets that you can cut on your own rather than paying to have them custom made for each shipment. Be sure you choose a denser foam that is easier to cut with a blade if you choose to fabricate your own foam inserts.