Drop-Test Driven Foam Pocket Design
Foam insert design informed by real drop-test data - cushion curves, G-force calculations, and foam thickness engineered to protect your product through the actual drops it will experience in shipping.
What It Is
Foam thickness and density selection is not guesswork - it's engineering. Each foam type and density has published cushion curves that show how much G-force is transmitted at different static stress loads and drop heights. We use this data to select the right foam type, density, and thickness for your product's fragility rating, weight, and expected drop height in the shipping environment.
- Cushion curve analysis for PE, EVA, and EPS foam grades
- Product fragility rating (G-force threshold) used to select foam spec
- Drop height determined by distribution environment (parcel, LTL, export)
- Foam thickness calculated to maintain G-force below fragility rating
- Static stress load (product weight / contact area) factored into density selection
- ISTA and ASTM drop-test protocols used as design reference
When You Need It
Fragile Electronics
G-force-rated foam keeps sensitive electronics below their damage threshold.
Medical Instruments
Precision instruments require validated foam design for compliance purposes.
Defense & Aerospace
MIL-spec packaging often requires documented cushion analysis.
Consumer Electronics
Drop-tested packaging reduces warranty returns from shipping damage.
High-Value Components
When one drop failure is more expensive than the entire packaging system.
Retail Packaging
ISTA-compliant packaging for retail programs requiring certification.
Engineered vs. Guessed Foam Selection
- We use published cushion curves - not rule-of-thumb foam thickness
- Product fragility rating drives foam specification before first prototype
- Prototype foam is the same grade specified by analysis - test data is valid
- Avoids over-engineering (too thick, too heavy, too expensive)
- Avoids under-engineering (product damage, returns, warranty claims)
- Documentation available for ISTA compliance and customer quality systems
Ready to Put This to Work?
Built in Wylie, TX - quoted fast, delivered faster.