Custom Foam Inserts and Interiors

Who are we?

Custom Equipment Cases for Presentation, Protection and Transportation

UK’s Leading Manufacturer of Custom Cases, Bags & Foam Inserts for Display, Transit Protection & Demo Kits – Designed for Sales, Marketing, Trade & OEM Clients.

PottertonPacs are experts in custom equipment cases and bags, along with our packaging foam insert manufacturers. Whether protecting products in transit or equipping your sales team with professional demo kits. We specifically design solutions to both display and protect your business’s sample products or equipment.

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Bulk and Die Cut Manufacturing

Launching a new product or shipping large orders? You need packaging that is fast, reliable, and budget friendly. That is exactly what our bulk manufacturing service provides. We make large

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Custom Foam Inserts and Interiors

When you need to protect valuable equipment or bring comfort back to your favourite furniture, finding the perfect fit is everything. This tailored approach significantly extends the lifespan of your

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Sales & Marketing Product Launch

Winning the Moment with Premium Presentation A successful product launch is the culmination of months, sometimes years, of intense product development and strategic planning. You have perfected the design, identified

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Custom Foam Inserts and Interiors

When you need to protect valuable equipment or bring comfort back to your favourite furniture, finding the perfect fit is everything. This tailored approach significantly extends the lifespan of your most treasured possessions. We deliver custom foam interiors tailored exactly to your needs. Whether you are upgrading flight cases for sensitive electronics or restoring your living room seating, we have the perfect foam solution for you. Our dedicated team works closely with you to ensure complete satisfaction every single time. Every project starts with understanding your goals. We specialise in high quality manufacturing that guarantees your items stay secure and comfortable. By utilising premium materials, we provide reliable protection you can trust for years.When you need to protect valuable equipment or bring comfort back to your favourite furniture, finding the perfect fit is everything.

We deliver custom foam interiors tailored exactly to your needs. Whether you are upgrading flight cases for sensitive electronics or restoring your living room seating, we have the perfect foam solution for you.

Every project starts with understanding your goals. We specialise in high quality manufacturing that guarantees your items stay secure and comfortable.

The Ultimate Custom Foam Solution

Forget standard blocks that waste space and look unprofessional. By choosing foam cut to size, you ensure your items remain completely secure during transit or daily use.

Here is how we do it:

  • Advanced Technology: Using our state of the art machinery, we transform raw materials into custom cut foam that meets your exact specifications.
  • Complete Precision: From simple rectangles to highly intricate layouts, our precision cut capabilities mean your items sit perfectly in their designated spots.
  • Total Customisation: We treat every custom shape foam request with absolute care, ensuring your custom foam inserts look and perform flawlessly.

Domestic and Commercial Applications

While we supply heavy duty packaging for commercial businesses, our bespoke foam services are also incredibly popular for domestic use.

A sagging couch can ruin the look of your living room. One of our most frequent requests is for replacement sofa cushions. By upgrading to quality foam, you can completely revive your furniture without the massive expense of buying a brand new suite.

We match the exact size and shape of your existing cushion covers, so your new inserts slide in perfectly and restore that original showroom comfort.

Just reach out to our team with your dimensions, say measure my foam please, and we will guide you through the easiest way to get your cut to size foam sorted!

Peli with Routed Interior

Choosing Your Foam Grades

Choosing your foam grades and selecting the right type of foam is the most critical step in your project. We stock a comprehensive range of foam grades to suit any application. Understanding these options guarantees you get the perfect balance of softness and long term durability. Low density foam is excellent for lightweight items and soft cushioning. It provides gentle support and is often used for packaging delicate consumer goods. In a home setting, this material is absolutely perfect for deeply plush back cushions. Medium density foam is the perfect middle ground, offering a great balance of support and give. This is a very popular choice for comfortable seating applications. It is widely used for dining chairs and average cases requiring reliable everyday protection. High density foam is essential for heavy equipment and premium seating that gets heavy daily use. It offers maximum protection and long lasting support. This robust material will not bottom out, making it the premier choice for longevity.

Explore Our Core Foam Services

We invite you to explore our core foam services. Ready to see how we build your protective interiors? Explore our three specialist areas to learn more about our manufacturing processes:

  • Precision CNC and engineering: Perfect for complex shapes, intricate depths, and absolute perfection for low volume orders. We use advanced routing technology to create inserts that contour exactly to your delicate gear. Explore our precision CNC and engineering services for your most specialised designs.
  • Bulk and die cut manufacturing: Rolling out a new product line? If you need thousands of identical inserts, our bulk manufacturing service is your best choice. Die cutting allows us to stamp out high volumes rapidly, giving you a highly cost effective solution. Learn more about our bulk and die cut manufacturing for high volume production.
  • Protection and benefits: Why is protective foam so critical? Beyond looking professional, the right inserts prevent costly transit damage and elevate your brand presentation. Discover the full protection and benefits of investing in our custom foam and case solutions.

Our Commitment to Excellence

Our commitment to excellence means we know that when you place an order, you want it quickly. Our streamlined production process ensures fast delivery without ever cutting corners on the finish of your product. Whether you need a single piece of foam for a cherished armchair or thousands of precision inserts for a global product launch, we have the expertise to make it happen.

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Get in touch, no pressure or obligation, Let’s Talk About Your project