Molded Cushion Process

We Will:

Step #1 Evaluate your packaging needs by reviewing your products fragility, weight             and dimensions. Review your distribution environmental and other special requirements.

Step #2 Calculate the minimum carton size and the correct amount of foam required to pass the ISTA drop test. We will discuss your requirements for any additional testing.

Step #3 Consider your on-hand quantity requirements and your shipping schedule to insure on time delivery and provide you the most cost effective product available. 

Step #4 At your request, perform a rudimentary drop test at your facility with a sample cushion. 
 

Step #5 Manufacture a mold box and mold images per our discussion and test results. 
 

Step #6 Manufacture and deliver cushions in sets for ease of use. When possible we will design universal cushions for an additional cost savings.

A wood mold is used to produce the desired cushion shape.                             Instamate film is plased in the mold and Instapak foam is dispensed.                          Your product is packaged safely in a custom-shaped engineered cushion.