A foam inlay must hold a product in place without making it unnecessarily difficult to remove. That is why fit, resilience, layer structure, and use are more important than just the color.
Start with the product
Measure the outer shape and determine which parts really need to be supported. A cutout does not always have to follow the complete contour. Add a finger cutout where necessary and prevent narrow strips of foam that can easily tear off.
Harder or softer foam
A firmer foam holds its shape and position better. A softer version may be more pleasant around vulnerable surfaces or shapes with small dimensional differences. Which choice is suitable depends on weight, frequency of use, and the way the packaging is transported.
Thickness and layer structure
A deep inlay can be built up from multiple layers. This allows you to design a bottom, contour layer, and top layer separately. Check that the product is sufficiently supported and does not protrude above the packaging.
Adhesive film
For suitable foam products, an adhesive layer can be chosen to secure a layer in a box, case, or other carrier. Adhesive film is an additional option and affects the price. Foam is not offered with protective film.
Order a prototype first
A digital contour does not tell you how much grip the final cutout will provide. For a new or critical inlay, have a prototype made first and test the actual product. Only then adjust the size, finger cutout, and layer structure for the full series.