Whether it's for transporting precision instruments over long distances or for daily storage of valuable items, aluminum cases provide a strong outer shell that acts as a protective barrier. However, to achieve comprehensive protection, the internal cushioning material is crucial. Various materials like EPE (expanded polyethylene), high-density foam, and EVA foam each have their own unique characteristics. Choosing the most suitable interior material is key to ensuring the safety of items inside the case. Let’s take a closer look at these commonly used interior materials in aluminum cases.
EPE (Expanded Polyethylene) Foam
EPE foam, short for expanded polyethylene, is a new environmentally friendly packaging material. It is soft, elastic, and features a surface made up of dense bubble-like structures, resembling rows of tiny pearls — hence the name. This structure gives EPE excellent cushioning properties. When the aluminum case is subjected to external impact, EPE can quickly disperse the force, effectively protecting the items inside.
EPE also boasts strong resistance to chemical corrosion and water, making it reliable even in humid or mildly contaminated environments. In practice, EPE is commonly used for packaging electronics, small appliances, and ceramic products. For example, in aluminum cases used to transport tablets, EPE can be cut to the appropriate shape to securely wrap the device, preventing collisions and scratches. For fragile ceramic tableware, its cushioning and shock-absorbing capabilities significantly reduce the breakage rate. Furthermore, EPE is lightweight and recyclable, reducing the overall weight of the aluminum case and aligning with eco-friendly practices.
High-Density Foam
High-density foam is characterized by its relatively high density, which gives it excellent support and compression resistance. It maintains a stable structure even under external pressure and does not easily deform, providing firm support for items inside the case. It is also highly durable and retains its shape and cushioning properties even after repeated use, making it ideal for aluminum cases subjected to frequent use.
This material is commonly used for storing photography equipment and medical instruments. For instance, DSLR cameras and professional lenses are both high-value and delicate, requiring stable support and protection. High-density foam can be cut to fit the shape of the equipment precisely, preventing movement and collision during transport. Similarly, it can protect medical instruments during transit, ensuring that they remain undamaged and function accurately.
EVA Foam
EVA foam, or ethylene-vinyl acetate copolymer foam, is a plastic-foam material with properties similar to traditional foam, even though it’s not classified as a sponge in the strict sense. EVA is soft, elastic, and able to absorb and disperse energy from impacts, offering reliable cushioning. It comes in various densities, so you can choose the appropriate hardness for your needs.
EVA foam is widely versatile. It can line the entire interior of an aluminum case or be precisely cut into specific grooves that fit the shape of the items being stored. For example, in aluminum cases for transporting electronic components, EVA foam can be shaped to hold each piece in place, preventing movement and impact. In premium gift boxes, its soft texture gently cushions the contents, enhancing the product’s perceived value. EVA also resists chemicals, moisture, and dampness, ensuring stable protection even in complex transportation environments.
Pick and Pluck Foam（DIY Foam）
Pick and pluck foam, often made from polyurethane, features a grid-cut surface and combines lightweight cushioning with modular storage functionality. The grid design helps distribute impact and improve airflow. Lower-density versions are soft and flexible, while higher-density options offer strong support. Users can remove sections of the foam to custom-fit their items.
This material is ideal for photographic and electronic equipment. It allows for precise separation and shock absorption, protecting items from scratches and collisions. Pick and pluck foam is a popular choice for modern portable cases and high-end storage cases.
Egg Foam
Egg foam has a unique wavy surface, which makes it particularly effective for sound absorption and cushioning. The raised and indented pattern increases the contact area with items, allowing it to disperse impact more effectively while absorbing vibrations and noise during transport.
It is a preferred choice for cases containing audio equipment and noise-sensitive instruments. For example, professional sound equipment requires protection not just from physical damage but also from noise interference. Egg crate foam reduces both vibration and noise impact, preserving sound quality. For delicate instruments like seismometers, it helps absorb transit vibrations and ensures precision is maintained.
Conclusion
The choice of protective materials inside the aluminum case is directly related to the safety and quality of the items inside the box. From pearl cotton and dense cotton for cushioning and shockproofing to flexible DIY cotton for high flexibility, each material has its irreplaceable advantages. At Lucky Case, we understand the importance of customization in providing the best protection for your products. As a trusted manufacturer of custom foam aluminum cases, we offer a wide range of foam options tailored to your specific needs. Contact us today to find the perfect aluminum case with foam solution for your business.
Post time: Feb-04-2026
