Packaging of objects can be done in a variety of ways and among them is custom foam packaging which is very common and will have to be applied in most cases where people are packaging regularly shaped objects. The procedure is very simple just for you to easily manage. It is important to make sure you are not using materials that can melt much easier since the process generates more heat hence, materials like chocolate are not recommended. Also, you are not advised to use substances that easily crushes sine there will be some pressure due to the foam expansion. The process is very simple and there are only a few materials that are required for you to start which include: paper cups, plastic spoons, scrap cardboard, plastic wrap, tape, a large knife, two-part polyurethane, and finally the rectangular container. Now, let’s have a look at the actual steps.
The starting point is for you to make sure you have wrapped the object very well in the plastic wrap that you are having for you to be able to protect the polyurethane well in the event that it is curing. The wrapping is also good to make it easy for you to remove it once it is well set. Now it is time for you to start creating the cardboard divider. Make sure you are cutting it into the shape of the container and not have to be perfectly centered and make sure you are making a hole in the object and finally, tapping of the object and the center is required of you. Mixing the polyurethane is the next step where you have to make sure you have combined the equal parts mix well in a paper cup and the plastic spoon will be used here for stirring. You need to know that the foam that you are using will have to expand very fast.
It is now the time for you to start pouring the foam into a container and make sure it is evenly distributing so that you are able to avoid air pockets with all expenses. Hence, you need to spend time distributing the foam, and also at the same time, you need to be assured that it is free from air pockets. The hard part that is awaiting you is for you to remove the container where you have to use some techniques so that you are able to manage that successfully. One of the ways is for you to start running a knife along the sides, afterwards, you need to turn it upside down and finally bang the countertop so that is will be able to become loose so that you will easily manage to remove it from the container.
After removal, you now need to start trimming and pull it apart. Here, there is some excess foam at either the top or bottom which you need to get rid of. Then make sure you have peeled off the plastic wrap, tape, and also the cardboard that you have used. Hence, you are not left with custom foam packaging inserts which represent a rectangular block that will hold your item safely.