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Foam Products, Assemblies and the Equipment Used to Make It

Posted by Ariana Loijos Spencer

Dec 11, 2020 11:17:31 AM

Foam is manufactured in buns (large blocks) or planks and may have to be cut or skived (trimmed or split to exact thicknesses) into sheets before it can be worked with. A foam packaging product has to then be custom cut and manufactured into smaller parts and often requires some assembly. There are many different fabrication technologies available depending on the shape, quantity, and quality that is required for the application, need for precision, and budget.

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Topics: Packaging, Foam, Equipments, Assemblies

Our Packaging Designs Save Time and Money

Posted by Jason Short

Oct 2, 2020 9:20:53 AM

A leading provider of scientific instruments for medical applications needed to ship blood analyzers to laboratories throughout the US and internationally. During Covid-19, compressing the timelines, and delivering medical equipment without damage due to shipping is paramount. Each blood analyzer weighed more than 500 lbs and had outer dimensions (OD) of approximately 36”x40”x46”. They approached LPC for better service and to quickly manufacture their current design which featured a floating base on a skid with a corrugated cover and internal foam cap.

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Topics: Packaging, Crates, shipping medical devices and robotics, Foam

Types of Industrial Packaging Foam and Their Applications

Posted by Ariana Loijos Spencer

Mar 27, 2020 3:59:02 PM

Every Application is Unique

Foam can be designed, cut, and fabricated to hold any shape. Many products have protrusions like flanges, brackets and buttons that change the overall surface of the product or have varying degrees of fragility or ability to bear weight, all of which can be accommodated with a foam packaging design.

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Topics: Packaging, Foam

Basics of Custom Industrial Foam Packaging

Posted by Ariana Loijos Spencer

Feb 25, 2020 1:40:09 PM

Why Use Foam in Industrial Packaging?

Foam is an effective cushioning and vibration dampening medium used in one-time and repetitive packaging of sensitive and/or fragile products. Foam can also be used for blocking and bracing and shock and vibration protection in crates and cases. Because foam is lightweight and relatively cheap to manufacture, it can protect a shipment during transit without adding substantial weight and cost.

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Topics: Packaging, Foam

Crating at First Class Packaging

Posted by LPC

Aug 15, 2019 12:52:00 AM

There is more than one way to package a product and that is why First Class Packaging is in the business of crating, cases, corrugated and foam.

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One Size Rarely Fits All – CNC Machine

Posted by LPC

Jun 10, 2019 12:48:00 AM

You simply cannot throw skillfully engineered equipment in a corrugated box with packaging peanuts and call it a day.

From an economist’s standpoint, that would be a terrible waste of money. Consider the time taken and the costs involved in your product. If you’re a startup company, you know all to well what is at stake. Your equipment needs to make it to the end user without damage and in proper working order. However, external factors are cumbersome and can ruin your device before it reaches your client. Shock, vibration, and static stress are just some of the factors that can ruin your reputation if you are not prepared.

Trust us to be prepared. Our design engineers work with you to manufacture custom foam inserts that protect your application against the harshest of conditions. Solid works is a design tool used by our engineers to intricately represent packaging solutions in a 3D format. Solid Works will communicate with the CNC machine to carve various materials such as polyethylene into the designated design. The CNC machine is adaptable and utilizes a blade or router to ensure smooth and clean cuts. The CNC blade works by making many precise incisions into a material with minimal debris, resulting in optimal clean lines. The CNC Router is capable of creating rounded shapes and multilevel indentations to perfectly hold your equipment. To ensure our custom foam inserts are the perfect fit we do everything in house at our warehouse in El Cajon. First Class Packaging is a Technical Packaging Dealer of Pelican-Hardigg cases, manufacturer of wood crates and a supplier of corrugated boxes.

See The CNC in Action:

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CMF-Metal Foam Shields the Warfighter

Posted by LPC

Mar 3, 2019 12:42:00 AM



We’ve seen countless composite metal foam (CMF) applications within the automotive, orthopedics, thermal and even interior design industries. Recent exploration by Scientists at North Carolina State University and the U.S. Army’s Aviation Applied Technology Directorate has lead to a new application for CMF that is astonishing.

Fortifying Composite Metal Foam Shields the Warfighter

U.S. Army explores the strength of CMF and it’s ability to protect tanks and combat vehicles. Traditionally, armor steel plates are used to shield the vehicles. By utilizing CMF, the armor weight of combat vehicles has the potential to be reduced by 65%. This could eventually lead to improved speeds and maneuverability.

“In one test, one inch of this remarkable foam faced off against an M2 .30 caliber armor piercing bullet. The bullet travels with 2,780 foot-pounds of energy and when it makes contact with the foam, that armor piercing round is Hulk-smashed by the foam (New foam armor for tanks can pulverize enemies).”

Tested against armor piercing rounds, explosions and extreme heat, the CMF proved remarkable.Improvised Explosive Devices (IEDs) cause detrimental damage. Foam armor absorbs the blast and lessens the traumatic effects of shock waves on the warfighter within. We congratulate the Scientists at North Carolina State University and the U.S. Army’s Aviation Applied Technology Directorate on the discovery and look forward to future findings on the miracle foam.

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An Up Close Look at Plywood

Posted by LPC

Jan 26, 2019 10:31:00 PM

Manufacturing Plywood Boards: Then and Now

Plywood is arguably the most underrated material. Consider the countless applications it is used in, ranging from recreational skateboards to industrial crating. Simply put, plywood is made by adhering thin sheets of wood together. These sheets are called veneer or plies. The process was vastly improved in the 1800’s with the creation of the Veneer Rotary Cutting Machine. The steam powered machine was capable of manufacturing longer and wider veneer sheets, all the while minimizing waste. It’s invention allowed for increased efficiency and lower costs, leading the way to large scale production runs.

Thank you to the V&A exhibition Plywood: Material of the Modern World (July- November 2017) for telling the story behind plywood.

The video below compares the manufacturing process in British Columbia, Canada, 1954 to Järvelä, Finland, 2016.

https://www.vam.ac.uk/plywood

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Why your packaging supplier should be a partner in your supply chain

Posted by Joe Marcal

Dec 26, 2018 11:00:00 AM

Custom industrial packaging is a service industry, because the packaging is customized to meet a specific application (a set of needs to ship a product to its point of use, and has unique requirements beyond the actual packaging material.) In fact, packaging is only part of "your problem": getting your product to it's point of use, which will require logistics, management, coordination, and other services. Most companies outsource their packaging, either to a supplier or a distributor, because it is not considered a strategic part of a company's value proposition. It is, however, an operational imperative. Ideally, packaging should be part of the new product introduction (NPI) planning process for a company's supply chain, with a goal of reducing complexity, and waste as well as streamlining communications.

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Topics: Packaging

Advantages of expanded (beaded) polyethylene foam over cross-linked polyethylene (XLPE)

Posted by Mark Hoffman

Sep 25, 2018 4:53:28 PM

When considering high performance foams for custom industrial packaging, expanded polyethylene foam (aka EPE or BPE) has several subtle but meaningful advantages over cross-linked polyethylene (aka XLPE) which result in superior packaging protection, cost savings on foam, and a lighter pack and is recyclable. Since both EPE and XLPE come from the same resin (PE) and both are molded buns or planks, one would expect the properties to be identical, but differences in the manufacturing process make EPE superior for a variety of packaging applications such as medical equipment, semiconductor equipment, IT servers, automotive class A surfaces, robotics, and other instrumentation.

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Topics: ATA Cases, Foam

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