Foam Fabrication

We specialize in precision-engineered custom foam fabrication, providing superior protection and tailored solutions for industries including medical, military, electronics, and industrial equipment. Our advanced capabilities include CNC foam routing, waterjet cutting, die-cutting, and laser cutting, allowing us to create highly customized foam inserts and packaging for ultimate product security.

MADE IN USA
AND GLOBALLY
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Foam Fabrication

Form. Function. Foam.

Discover the perfect balance of protection and precision with our custom foam solutions, engineered to safeguard, cushion, and enhance your products.

Precision-Cut Foam Inserts

Our custom foam inserts are engineered to provide superior protection and organization for sensitive equipment. Using CNC routing, waterjet cutting, die-cutting, and laser-cutting techniques, we create highly detailed and precisely shaped foam solutions. Whether for medical devices, military gear, or industrial tools, our inserts are designed for a perfect fit, ensuring maximum impact resistance and security.

Made to order

We manage the entire foam design and manufacturing process in-house, ensuring precision and efficiency. Starting with high-volume foam loaves, each piece is expertly cut to exact dimensions, optimizing both protection and cost-effectiveness.

Extensive Options

We work with Polyethylene (PE), Polyurethane (PU), cross-linked foam, convoluted foam, anti-static foam, and ESD-Safe foam to build the perfect application for your product.

Elevate Your Brand

Put the finishing touches on your case or packaging foam with custom branding. We offer foam laser etching, layering, inlays and color matching to give your case a high end look and feel.

Packing Solutions

Whether you need accessible packaging foam or specialized product protection, our in-house engineers design and manufacture custom solutions tailored to your exact needs.

Ready for a Test Run?

Request A Sample
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The Royal Treatment

DESIGNED. DEVELOPED. DELIVERED.

A dedicated project manager is with you every step of the process, creating a seamless, efficient experience.

DESIGN CONSULTATION

Collaborate with Royal Case's experienced specialists to design a custom case tailored to your specific needs.
PROTOTYPE
Receive a working prototype of your custom case, allowing you to evaluate and approve the design before full-scale production begins.
PRODUCTION
Upon approval, your custom case enters production, utilizing our extensive manufacturing capabilities to ensure the highest quality output.
INSPECTION
Your order undergoes rigorous quality control checks to meet every standard, ensuring durability and functionality.
DELIVERY
Finished products are stored in our expansive warehousing facilities and shipped to your specified location, ensuring timely and efficient delivery.

BLOG: Foam Fabrication

Everything you need to know about foam fabrication.