2026-09-21 · KeXinMaterials 編集チーム
B2B バイヤー向けカスタムフォームインサートケース設計ガイド (2026)
保護価値の 80% はフォーム内部にあります。このガイドは 3 つの主要なフォームシステム — CNC カット、ピック・アンド・プラック、層状 — を素材、密度、製造コスト、B2B ワークフローで比較します。
なぜフォームの選択が保護ケースの価値を決定するか
Two cases with identical shells and certifications can have radically different field performance depending on the foam interior. Foam absorbs 60-80% of impact energy transmitted to the contents.
Most B2B buyers focus on shell spec — IP rating, MIL-STD drop test, latch cycle. But the foam insert is what protects the actual contents. A well-designed foam cutout localises impact forces to non-critical areas of the equipment, prevents abrasion during transit, and organises gear for fast deployment.
For expensive equipment — thermal imaging cameras, surveying instruments, medical defibrillators, defence radios — the foam is mission-critical. A poor foam choice can destroy gear even when the shell survives.
Foam choice also drives 30-50% of total case cost and 7-15 days of lead time. B2B buyers should evaluate foam alongside shell spec, not as an afterthought.
3 つのフォームシステム:CNC カット vs ピック・アンド・プラック vs 層状
Each foam system suits different B2B use cases. Match system to equipment value, deployment pattern, and order volume.
CNC-cut foam is the precision option. A factory cuts individual cavities to match exact equipment dimensions using a CNC knife or hot wire. Each cavity can be tuned for density, depth, and finger-pull access. Best when equipment value justifies the precision and content does not change frequently.
Pick-and-pluck foam is the field-flexible option. Pre-scored cubes can be plucked out by hand to fit gear. Buyer can reconfigure for new equipment without factory involvement. Best for mixed kits, service vans, photographers, and B2B programmes with frequent gear changes.
Layered foam (often convoluted "egg-crate" or flat stacked layers) is the lid-only option. Provides blanket cushioning on the inside of the case lid. Often combined with pick-and-pluck base. Best for general impact protection when exact equipment shape is not critical.
| Attribute | CNC-Cut Foam | Pick-and-Pluck | Layered Foam (Egg-Crate / Convolute) |
|---|---|---|---|
| Best for | High-value precision equipment | Mixed gear, frequent changes | Generic top-lid protection |
| Material | Polyurethane (PU) or Polyethylene (PE) | Polyethylene (PE) pre-scored | Polyurethane (PU) convoluted |
| Density | 30-50 kg/m³ (custom) | 25-35 kg/m³ (fixed) | 20-30 kg/m³ |
| Precision fit | ±0.5mm (tight) | User-defined (rough) | None (blanket protection) |
| Fabrication cost | USD 50-200 per cavity | USD 5-15 per case | USD 3-8 per case |
| Lead time | 7-14 days (factory) | Same-day (self) | Same-day (stock SKU) |
| MOQ for custom | 10+ cases (shared CNC file) | None (off-the-shelf) | None (off-the-shelf) |
| Reusability after content change | Low (single-purpose) | High (re-pickable) | Medium (compression set) |
| Typical B2B application | Defence radio, medical device, surveying instrument | Field service kit, photographer gear | Camera lid, generic top protection |
素材:ポリウレタン (PU) vs ポリエチレン (PE) vs EVA
Foam material drives cost, density, water resistance, and chemical compatibility. Three options dominate B2B case interiors.
Polyurethane (PU) foam is the soft, open-cell option. Density 30-50 kg/m³. Excellent shock absorption for fragile equipment (cameras, instruments, glass). Absorbs water — not suitable for marine / outdoor use without sealed bag. Custom colours available. Cost: medium.
Polyethylene (PE) foam is the firm, closed-cell option. Density 25-45 kg/m³. Waterproof, chemical-resistant, and reusable. The standard pick-and-pluck material. Custom CNC-cut possible but harder than PU. Cost: low-medium.
EVA foam (Ethylene-Vinyl Acetate) is the high-rebound option. Density 30-80 kg/m³. Used for premium camera and instrument interiors where tactile feel and rebound matter. Closed-cell, water-resistant. Cost: high.
At KeXinMaterials we stock PU (30-45 kg/m³) and PE (28-35 kg/m³) for CNC-cut work. EVA available on request for premium SKUs. Pick-and-pluck always PE (waterproof). Convoluted lid PU (compression-set recovery).
密度選択:機器に合わせたフォーム
Foam density determines how impact energy is absorbed. Three rules of thumb cover 90% of B2B procurement cases.
- Light equipment (under 2 kg, fragile optics): 30-35 kg/m³ PU. Soft cushion, slow rebound, absorbs micro-vibration.
- Medium equipment (2-10 kg, mixed use): 35-45 kg/m³ PU or PE. Standard protection for cameras, surveying gear, instruments.
- Heavy equipment (10+ kg, defence / industrial): 45-60 kg/m³ PU or PE. High-density load-bearing foam for radios, weapons, medical carts.
- Anti-static requirement (electronics): PU or PE with anti-static additive. Surface resistivity 10⁹-10¹¹ Ω. Verified per SKU.
- ESD-sensitive (PCB, SSD): Conductive PU, surface resistivity 10³-10⁶ Ω. Specify in RFP.
CNC フォーム設計ワークフロー:図面 から生産まで 7 日
A precision CNC foam project takes 7-14 days end-to-end. The buyer's role: provide accurate equipment drawings.
- Day 1-2: Equipment geometry. Buyer sends equipment 3D drawing (STEP / IGES) or 2D drawing with key dimensions. For organic shapes, physical sample shipped to factory.
- Day 3-4: Foam cavity design. Factory designer drafts cavity layout in CAD: 1-2mm clearance around each item, finger grips for retrieval, labelling panel.
- Day 5-7: Sample production. 1-3 sample foam inserts produced via CNC hot wire or knife. Shipped via DHL to buyer for evaluation.
- Day 8-10: Sample evaluation. Buyer fits equipment, marks required adjustments. Factory revises and re-cuts if needed.
- Day 11-14: Mass production. 100+ foam inserts produced per approved design. In-line QC: cavity depth, dimension tolerance, finger grip accessibility.
- Day 15+: Foam install + lid foam. Foam inserts installed into case shells. Convoluted or flat PU added to lid for top-down impact protection.
- Day 21-30: Shipment. Foam installed, case closed, packed, shipped FOB Shenzhen / FOB Ningbo.
よくあるフォーム設計ミス
Five recurring foam design errors cost B2B buyers 10-25% of protective case effectiveness. Avoid them upfront.
- Mistake 1: Cavities too tight. Equipment does not fit on assembly day, or fits but cannot be retrieved. Spec 1-2mm clearance on each side.
- Mistake 2: No finger grips. Foam must allow easy retrieval in field. Designer adds 5-10mm finger slot or thumb cutout to each cavity.
- Mistake 3: Wrong density. Soft foam + heavy equipment = equipment bottoms out under load. Heavy equipment needs higher density.
- Mistake 4: Lid foam forgotten. Top-down impact protection requires lid foam (convoluted PU, 15-25mm thick). Skipping it defeats MIL-STD-810G top drop test.
- Mistake 5: Foam absorbs water. PU is open-cell; absorbs water in marine / outdoor use. Use PE for marine, or seal PU in waterproof liner.
なぜカスタムフォームケースに KeXinMaterials を選ぶのか
We have produced over 5,000 custom foam inserts since 2014. 30+ designers fluent in SolidWorks, AutoCAD, and Fusion 360. CNC hot-wire cutting on 4 production lines.
Standard material stock: PU 30-45 kg/m³, PE 28-35 kg/m³, EVA 35-55 kg/m³. Anti-static PU available. Conductive PU on request for ESD-sensitive electronics.
Anti-static additive available for electronics. Conductive PU (10³-10⁶ Ω surface) for ESD-sensitive PCBs / SSDs.
Sample lead time 7-10 days. Mass production 10-14 days after sample approval. Integrated with case shell production for 30-45 day end-to-end OEM delivery.
We export foam-buffed cases to USA, UK, Germany, Canada, Japan, Russia, Philippines, India, HK/TW, Middle East. Trade terms: EXW Shenzhen / FOB Shenzhen / FOB Ningbo.
重要なポイント
- KeXinMaterials — 2014 年からのソース工場、5,000+ のカスタムフォームインサートを生産
- 3 つのフォームシステム:CNC カット(精密)/ ピック・アンド・プラック(柔軟)/ 層状(ブランケット)
- 素材:PU(柔らかい、壊れやすい光学系)/ PE(硬い、防水)/ EVA(プレミアム、高反発)
- 密度 30-50 kg/m³ 壊れやすい / 35-45 kg/m³ 標準 / 45-60 kg/m³ 重防衛
- サンプル 7-10 日、量産 10-14 日、統合 30-45 日エンドツーエンド OEM
よくある質問
CNC カットフォームとピック・アンド・プラックフォームの違いは?
CNC カットフォームは工場機械(ナイフまたは熱線)で精密にカットされ、特定の機器の形状に合わせます。各キャビティは ±0.5mm。製造コスト USD 50-200/キャビティ、リードタイム 7-14 日。ピック・アンド・プラックフォームはキューブ状にプレカット済み;ユーザーが手でキューブを引き抜き機器に合わせます。コスト USD 5-15/ケース、即時セットアップ、完全に再構成可能。CNC カットは高価値精密機器に適し、ピック・アンド・プラックは柔軟/混合キットに適します。
機器にはどのフォーム密度を選べばよいですか?
軽量機器(2kg 未満、壊れやすい光学系):30-35 kg/m³ PU。中量機器(2-10kg):35-45 kg/m³ PU または PE。重量機器(10+kg、防衛/産業):45-60 kg/m³ PU または PE。静電気防止電子機器には、抗静电添加剤入り PU(表面抵抗率 10⁹-10¹¹ Ω)を指定。ESD 敏感 PCB/SSD には、導電性 PU(10³-10⁶ Ω)を指定。
フォーム内装は特定の機器向けにカスタマイズできますか?
はい。機器の 3D 図面(STEP / IGES)または主要寸法を含む 2D 図面を提出してください。工場設計者が CAD で 1-2mm クリアランスとフィンガーグリップ付きのキャビティレイアウトを設計します。サンプルは 7-10 日で生産。サンプル承認後 10-14 日で量産。サンプル料金 USD 50-200(大量注文に含まれる場合が多い)。
カスタムフォームの生産にはどのくらい時間がかかりますか?
サンプル 7-10 日(1-3 サンプルインサート)。量産 10-14 日(100+ インサート)。ケースシェル生産と統合され、30-45 日のエンドツーエンド OEM 納品。取引条件:EXW 深圳 / FOB 深圳 / FOB 寧波。
CNC カットフォームインサートのコストは?
幾何形状の複雑さと素材により、USD 50-200/キャビティ。PE は PU より安価;EVA はプレミアム。セットアップ料 USD 50-100 が単価に償却。典型的な 4 キャビティのカメラ/機器インサートの場合、フォームのみで USD 200-500/ケース。シェル USD 60-150 を加えると、合計 USD 260-650/ケース FOB 深圳。
静電気防止フォームはありますか?
はい。表面抵抗率 10⁹-10¹¹ Ω の静電気防止 PU が利用可能(電子機器業界標準)。ESD 敏感 PCB/SSD 用には導電性 PU(10³-10⁶ Ω)。静電気防止添加剤は CNC カットとピック・アンド・プラックに対応。サンプル段階で仕様を確認;SKU ごとに静電気減衰テスト証明書を提供。