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Custom Foam Converters & Bespoke Interior Solutions

Bespoke die cut polyether foam inserts with cut outs to CNC routed or water jet cut plastazote, trays or dividers.  Options for foam conversion & customised interiors are endless!


Whether you require a promotional packaging solution, a protective enclosure or a sample presentation case then you need look no further.  Sourcing the outer case, bag or folder may only be your first step and now you need an interior solution?  PottertonPacs are  foam converters & engineering specialists and have a vast range of options for customising the interiors of our cases, bags or folders.  Foam interiors are not the only solution on offer either, we also offer custom welded, stitched, moulded and fabricated interior solutions too. (minimum quantity or design/tooling fee's may apply)  

Customising options include

  • custom die cut, cnc routed or water jet cut foam or plastazote
  • vacuum formed trays/inserts
  • product display boards
  • printed interior display panels
  • product mounting plates


With one of the broadest ranges of bespoke interior solutions on the market PottertonPacs are confident we will be able to propose a custom interior solution to suit your needs.

To follow are just a few details to help you understand some of the most popular products and processes our customers choose for bespoke interiors.  Of course if you would sooner speak with one of our experienced team regarding foam conversion or another other custom interior options that could offer a solution to your requirement then we would be happy to answer any of your questions or recommend a possible solution for your consideration.

What is plastazote?
Plastazote is a high-density closed cell foam made from polyethylene offering maximum lightweight protection.  Plastazote is commonly the choice for high value or delicate equipment.  Plastazote can be diecut, CNC routed or water jet cut and can be produced with contrasting coloured finishes so removed components are easily recognised.


What is CNC Routing?
A fully computerised process of machine routing the plastazote using a CAD programme.  CNC routing allows complex shapes to be precision cut at speed to provide a consistent and exact fit.  Commonly used for the interiors of delicate equipment cases, pharmaceutical or medical cases, instrument or electronic component packaging & heavy equipment.  CNC routed inserts provide a high quality, precise finish. 

Whats is polyether foam?
Polyether foam Is a open cell, medium load bearing open cell foam.  Polyether foam is especially effective as presentation packaging foam for custom case interiors.  This open cell foam is available in 3 options as shown below.


     Plain Grey Polyether Foam                Profile Foam / Eggbox Foam            Pick and Pluck / Pre Cubed 
                                                      Polyether Foam                                      Polyether

What is die cut foam?
Die cutting is the process used to press cut component shapes into foam using a specialist cutting knife.  A knife has to be created using specially fabricated blades which are inserted into a plywood block to create the perimeter outline of the products or components to be held in the foam.  This method of creating customised foam interiors achieves a repeatedly accurate, high quality finish at a competitive price.

                              Knife                             Plain Grey Foam with Cut Outs              Nylon Topped Foam with Cut Outs

Corporate Colours
A variety of coloured nylon topped laminated foams are available to incorporate your company or brand colour and contrasting coloured tops also promote easy visability of missing products or components. Adding colour variation optimises the visual appearance and adds to the overall finish to your custom

Nylon topped foam colour options

Stock standard colours: (1) Black   (2) Medici Blue   
Available to order: (3) Red  (4) Gull Grey   (5) Gun Metal Grey
                              (6) Green   (7) Navy   (8) Burgundy

Vacuum formed trays & inserts
Vacuum formed inserts are made using a mould which depending on the size of the production run can be produced in wood, resin or aluminium. Vacuum formed inserts are particularly well suited for high volume users as tooling is required to produce this type of insert.

Product display and sampleboards
Suited to smaller more intricate item, product boards usually have a series of elasticated loops to hold items in place for display.

Product Identity
This process allows for a product list and/or visual presentation to be displayed in the interior of the case, bag or folder.  The product list enables customers or representatives to easily locate the required component. 

For further information on any of our bespoke interior options please contact us either by telephone on 0116 2767562 or by email at