CNC Routing, waterjet & Die Cutting
How can i scale our brand?
Custom, bespoke & tailored
How will it help my business?
Precision Processes for Scalable,
Tailored Solutions
For businesses that depend on professional, secure and consistent product presentation, precision-cut foam inserts offer an unbeatable combination of protection, organisation, and impact. At PottertonPacs, we use decades of foam conversion experience and advanced manufacturing capabilities to deliver tailored foam insert solutions that support larger order requirements with exceptional consistency.
Our processes are designed for organisations who need to protect or present equipment, tools, or products in a way that reflects the quality of their brand. Every insert is custom manufactured to exact specifications, ensuring reliability, accuracy and a professional finish across all units produced.
We use four core foam conversion technologies — band knife cutting, CNC routing, waterjet cutting, and die-cutting — each suited to different applications and production needs.
CNC ROUTING advantages?
CNC Routing: Technical Accuracy Without the Tooling Cost
CNC (Computer Numerical Control) routing is ideal for creating complex, fully tailored layouts with exceptional precision. Using CAD (Computer-Aided Design), our routing systems cut clean, accurate recesses into materials such as Plastazote (PE closed-cell) foam the most popular choice for durable and professional inserts.
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Key advantages:
- Creates complex, bespoke layouts to exact measurements
- Delivers consistent quality for repeat orders
- Allows multiple depths within one layout for better presentation
- Ideal for scaling up production efficiently
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CNC routing is widely used for technical kits, equipment protection, and branded presentation cases.
Waterjet Cutting: Advanced Detail with Flexible Output
Waterjet cutting uses a fine, high-pressure jet of water to create exceptionally clean cuts without altering the structure of the foam. This method is highly effective for intricate layouts, sharp edges and shapes that require precision detail.
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Key advantages:
- No tooling required ideal for flexible production runs
- Produces sharp detail, fine cuts, and tight corners
- Fast and accurate processing
- Compatible with Plastazote and other PE foams in a range of densities and colours
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This process is well suited to projects where detail and accuracy are critical, including medical device packaging, promotional sample kits, and specialist equipment protection.
Advantages of die cutting?
Die-Cutting: Cost-Efficient for Repeat Orders
For repeatable layouts and larger quantities, die-cutting offers a cost-effective solution. Using a specially fabricated cutting knife and hydraulic flatbed press, this method allows multiple inserts or pads to be produced in one pass — making it ideal for businesses that need a consistent, repeatable output.
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Key advantages:
- Excellent for bulk production runs and repeat layouts
- Delivers uniform quality across every unit
- Low per-unit cost after initial knife investment
- Perfect for packaging, promotional kits and tool inserts
need help with choosing?
Choosing the Right Foam Conversion Method
Each cutting process CNC routing, waterjet cutting, and die-cutting has its own strengths. The most suitable choice depends on factors like shape complexity, production quantity, and budget.
To support your decision, we can provide pre-production samples or pilot batches, ensuring your foam solution is perfectly engineered before full production begins.
Why choose us?
Why Partner with PottertonPacs?
– UK-based manufacturing expertise built on decades of industry experience
– Custom, bespoke, and fully tailored solutions to match your product and brand
– Reliable scalability for larger order requirements
– Consistent quality across every insert produced
– Professional finish designed to enhance product presentation and protection
Our team works closely with businesses across multiple sectors from medical and pharmaceutical to engineering and promotional to deliver foam solutions that are accurate, dependable, and cost-effective.
Why PottertonPacs?
Reliable Expertise - Backed by Quality
Years Of Experience
Trusted Quality
Custom for You
Protect & Impress
What does everyone say?
LATEST REVIEWS
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UK’s Leading Manufacturer of Custom Cases, Bags & Foam Inserts for Display, Transit Protection & Demo Kits – Designed for Sales, Marketing, Trade & OEM Clients.
