When it comes to shipping delicate products, protection is everything. Foam packaging plays a vital role in safeguarding valuable items, from electronics and appliances to medical devices and precision instruments, from shock, vibration, and environmental stress. It’s engineered protection that helps prevent costly damage, reduce returns, and keep customers confident in your brand.

At Wasatch Container, we combine design expertise with performance testing to create foam packaging that performs under real-world conditions. Using ASTM D4168 testing standards such as drop tests, G-force measurement, and energy absorption curves, we evaluate how each design absorbs impact to ensure your products arrive safely every time.

Selecting the Right Foam

Each foam material offers unique benefits and choosing the right one depends on how it needs to perform.

  • Polyethylene (PE) is dense, resilient, and resistant to water and chemicals, making it ideal for reusable crates and heavy-duty applications.
  • Polyurethane (PU) provides softer cushioning for delicate electronics or medical devices that require gentle handling.
  • Expanded Polystyrene (EPS) offers a lightweight, cost-effective option for single-use packaging.
  • Anti-static foam prevents electrostatic discharge, protecting sensitive electronic components.
  • And for a refined finish, cross-linked PE (XLPE) delivers strength, smooth texture, and lasting shape, perfect for automotive, optics, or high-value goods.

Engineered with Precision

We’ve invested in advanced equipment to ensure every insert fits and functions perfectly from design to final assembly. Each machine plays a key role in creating packaging that protects, presents, and performs.

  • Waterjet Cutting – Using a high-pressure stream of water, our waterjet machines cut through foam with ultra-precise accuracy — achieving tolerances as tight as ±1/32”. This process creates clean edges and intricate shapes without heat distortion, ideal for high-end or delicate components.
  • CNC Routing (Computer Numerical Control) – Our CNC routing technology uses computer-guided cutting to carve custom cavities and layered builds with pinpoint precision. This product is perfect for items requiring snug, repeatable fits across multiple layers of foam, ensuring consistent protection and presentation.
  • Hot Wire & Die Cutting – For larger runs or uniform shapes, these cutting methods deliver efficiency and consistency. The hot wire allows for smooth contour cuts on expanded foam materials, while die cutting is used for repetitive precision at scale.
  • Adhesive Lamination – When projects demand multiple layers or varied foam densities, our lamination system bonds them seamlessly. The result is multi-layer protection that combines rigidity, cushioning, and durability, all in one engineered solution.

We also offer kitting and assembly to create complete, multi-component systems that look professional and perform reliably.

Protection That Performs

Foam packaging does more than protect, it improves efficiency. Lightweight materials help lower freight costs, while custom inserts streamline packing and elevate product presentation.

For over 30 years, Wasatch Container has delivered proven packaging performance through innovation, precision, and craftsmanship. Whether you need reusable crates, custom inserts, or high-end presentation packaging, our foam solutions are built to protect every shipment, every time.

Contact us today to learn more about our engineered foam packaging solutions.