PFI provides custom die-cut foam inserts that secure fragile, high-value products and protect them from damage during shipping and handling. We precision-cut each cavity to match the exact shape of your product, keeping it securely in place while absorbing shock and impact in transit. From individual electronics enclosures to full production runs of instrument cases, PFI engineers die-cut foam inserts for a precise fit, reliable protection, and consistent performance.
Lower Than National Pricing
Delivery Across SoCal
Nationwide Shipping
CAD Design & Prototypes
PFI designs and produces custom die-cut foam inserts, packaging, and parts for manufacturers across every industry. Using CAD-engineered patterns and precision cutting tools, we turn your product dimensions into foam that cradles each item exactly where it needs support. The result is packaging that protects better, uses less material, and moves your pack-out line faster.
Whether you need protective inserts for shipping, foam gaskets and seals for assemblies, or cut-to-size pads for kitting, we match the foam grade and the cut to your exact application.
Every project starts with your specs and ends with foam that performs. We help you choose the right density, thickness, and material, then cut to tight tolerances so each part drops into place on the line without trimming or guesswork. Order a small first run to prove the design, then scale to volume with consistent, repeatable results.
The right foam depends on what you are protecting, how it ships, and the environment it moves through. We stock and die-cut a full range of materials, and we will recommend the best fit for your product and budget.
A durable, closed-cell foam that resists moisture and chemicals. PE is the workhorse choice for blocking, bracing, and rugged shipping inserts that take repeated handling.
Soft and highly conforming, PU foam cushions delicate items such as glassware, optics, and instruments. Its open-cell structure cradles irregular shapes and absorbs shock on all sides.
A premium closed-cell foam with a smooth, clean finish and fine cell structure. XLPE suits medical devices, aerospace parts, and high-end products where both protection and presentation matter.
Engineered for electronics, this foam dissipates static while it cushions. Available in anti-static and conductive grades, it protects circuit boards, sensors, and components from electrostatic discharge in transit and storage.
Dense and resilient with a professional look, die-cut EVA foam is ideal for tool control inserts, case foam, and presentation packaging that needs to hold shape through heavy use.
Rigid and lightweight, EPS delivers cost-effective protection for bulky or heavy items and works well for molded-style blocks, trays, and corner support.
Send us your part dimensions, a drawing, or a sample. Our team builds a CAD pattern that maps every cavity, so the foam supports your product precisely where it counts.
We produce a prototype for you to test with your actual product and shipping conditions. You confirm the fit before any full production run, which removes risk and rework.
Once the design is approved, we cut your foam to tight, repeatable tolerances. Consistent parts mean a smoother pack-out line and dependable protection on every unit.
Each order is inspected, then shipped on your schedule with next-day delivery across Southern California and free nationwide shipping through our distribution network.
Custom inserts secure parts and assemblies during transit, cutting movement, scuffing, and costly damage across the supply chain.
Precision-cut foam cradles sensitive components and tooling, meeting strict handling standards and supporting compliant, damage-free transport.
Tailored foam protects products in transit while lifting the unboxing experience, reducing returns and reinforcing your brand.
Clean, non-abrasive foam holds delicate instruments and medical devices securely, protecting calibration and sterility from the plant to the point of use.
Die-cut foam parts, gaskets, and pads improve pack-out efficiency, protect finished goods, and reduce wasted material on the line.
Anti-static and ESD foam inserts protect circuit boards, sensors, and devices from static, shock, and vibration through shipping and handling.
CAD-engineered patterns and tight cutting tolerances give you inserts that seat perfectly and repeat unit after unit.
From soft PU to rugged PE, static-safe ESD, and clean XLPE, we match the material and density to your product and environment.
Our pricing typically runs 15% to 40% below national competitors, with smart design that trims material waste on every run.
Test a free prototype before you commit, then rely on next-day local delivery and free nationwide shipping to keep your line supplied.
We provide local next-day die-cut foam delivery across Southern California:
Multi-location and out-of-state businesses ship from our nationwide distribution centers in CA, TX, IL, PA, TN, and GA, so you get consistent foam packaging wherever you operate.
Send us your part, your drawing, or your dimensions, and our engineers will design a die-cut foam solution that protects it and lowers your packaging cost. Test a free prototype, then scale with confidence.
Die-cut foam is foam that is cut into a precise shape using a shaped cutting die or CNC-guided blade. The process creates custom cavities, inserts, gaskets, and pads that match a product exactly, so items sit securely and stay protected during shipping, storage, and handling.
PFI die-cuts polyethylene (PE), polyurethane (PU), cross-linked polyethylene (XLPE), EVA, expanded polystyrene (EPS), and ESD or anti-static foam. We help you choose the right density and thickness based on your product weight, fragility, and shipping environment.
Yes. We specialize in custom die-cut foam engineered to your exact dimensions. Share a sample, a drawing, or your measurements, and our team builds a CAD pattern, produces a free prototype for you to test, and then cuts your inserts to tight, repeatable tolerances.
Absolutely. Die-cut foam is a common choice for gaskets, seals, and cushioning pads in assemblies and enclosures. We cut closed-cell and specialty foams to your gasket specs, including adhesive-backed options for fast, clean installation.
Yes. We supply ESD and anti-static die-cut foam for electronics and sensitive components. These grades dissipate static while cushioning, protecting circuit boards, sensors, and devices from electrostatic discharge alongside shock and vibration.
Electronics, medical devices, aerospace and defense, automotive, industrial manufacturing, and retail or e-commerce all rely on die-cut foam. Any business shipping fragile, high-value, or irregularly shaped products benefits from a precise, protective foam fit.
Standard foam sheets are flat, cut-to-size material you fabricate yourself. Die-cut foam arrives ready to use, shaped to your product with engineered cavities and clean edges, which speeds up your pack-out line and delivers consistent protection on every unit.
We offer next-day delivery across Orange, Los Angeles, San Diego, Riverside, and Ventura counties, plus free nationwide shipping from distribution centers in six states. Vendor-Managed Inventory and Just-in-Time programs keep your foam arriving exactly when you need it.
Fill out the Request a Free Quote form or call our team. Include your product type, dimensions, foam preference, and volume, along with any special needs such as ESD protection or adhesive backing. Most quotes go out within one business day.
