Foam and Paper Inserts
Custom die-cut foam and paperboard inserts for medical device protection, positioning, and presentation. Engineered to immobilize your device precisely within its primary or secondary packaging.
Foam and paper inserts serve a critical function in medical device packaging — holding the device in a fixed, controlled position to prevent movement-related damage during shipping, storage, and sterilization. At PPR, we supply custom die-cut foam and paperboard inserts in a range of materials and densities, engineered to your device geometry and packaging configuration.Die-Cut Polyethylene Foam
Die-Cut Polyethylene Foam
Low-density (1.2–2.2 lb/ft³) and high-density (2.2–4.0 lb/ft³) polyethylene foam die-cut to fit your device precisely. Closed-cell construction resists moisture and particulate generation.
Polyurethane Foam Inserts
Open-cell polyurethane foam for applications requiring conformable cushioning. Available in multiple densities and colors. Common in transport and presentation packaging.
Anti-Static Foam
Pink polyethylene anti-static foam for medical devices containing electronic components. Prevents ESD damage during packaging, storage, and transport.
Cross-Linked PE Foam
Fine-cell, cross-linked polyethylene foam for consistent density, smooth surface finish, and resistance to compression set. Common in precision device inserts.
Paperboard Inserts & Dividers
Die-cut chipboard, SBS, and corrugated paperboard inserts for lightweight device positioning, kit organization, and IFU display within folding cartons and rigid boxes.
Multi-Layer Insert Systems
Layered insert systems combining foam and paperboard for complex device configurations — positioning the device at the correct depth while protecting all surfaces and projections.
Standard Process:
Discovery & Requirements
Device specs, sterilization method, use environment, and regulatory pathwayreviewed with your team.
Design + Development
Artwork and specification sheets provided, or new packaging concepts engineeredby our team.
Prototypes + Proposal
Prototypes available for testing and validation. Once approved, pricing and termsare determined.
Validation
IQ/OQ/PQ executed. Accelerated aging and distribution simulation testingcompleted per ISO 11607.
Final Approval + Production
Proofs made to match drawings and specifications. Validated design transferred tofull production.
Materials & Options
- Polyethylene Foam
Closed-cell, low particulate, ETO/gamma compatible - Polyurethane Foam
Open-cell, conformable, multiple densities - Cross-linked PE
Fine cell, consistent density - Anti-static Foam
ESD protection, ANSI/ESD S541 - Paperboard
Multiple thicknesses, chipboard, SBS and corrugate available
Device Categories We Support
Foam and Paper Inserts
We design foam and paper inserts as part of the complete packaging system — not as an afterthought. Proper insert design prevents device damage, reduces warranty claims, and protects sterile barrier integrity.
Every insert is profiled to your device geometry — not a standard cavity. This prevents movement, protects projections, and eliminates the damage that generic inserts miss.
