Keep electronic components neat, safe, and easy to find. Custom ESD foam inserts provide shaped spaces for each product or part. The foam helps protect against static electricity and limits movement inside the package. It can support small tools, circuit boards, connectors, sensors, and many other sensitive items.
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Protect boards, chips, sensors, drives, tools, and other electronics with packaging that fits each part. Custom Boxes Tech makes wholesale custom ESD foam inserts for shipping, storage, retail kits, repair sets, and device cases. Our team shapes each cavity around the product.
You also get free design support, a free sample, 24/7 customer care, quality checks, and after-sale help from CBT. Send your product size and quantity to get a free sample and the wholesale ESD insert quote today.
A good insert keeps parts in place and gives fingers room to lift them out. We plan pocket size, wall width, lid space, and foam depth around your product.
For custom ESD foam packaging for circuit boards, we can add slots for cables, adapters, probes, leads, and small parts. The layout can hold one item or a full kit without making packing hard.
Different ESD foams do different jobs. Conductive polyethylene gives firm support. Static dissipative foam helps control charge. Open-cell polyurethane gives a soft cushion for light parts.
Common thicknesses: 1/8, 1/4, 3/8, 1/2, 3/4, and 1 in
Reference densities: about 1.3–3.1 lb/ft³
Some conductive PE grades: surface resistance below 1 × 10⁴ ohms
Some dissipative grades: 1 × 10⁴ to below 1 × 10¹¹ ohms
Material values vary by grade, supplier, and test method
CBT matches the insert to the use case instead of treating every pink or black foam as equal.
We can make small trays, mid-size device inserts, or large layered sets.
Insert Size | Thickness | Common Use | U.S. Budget Price |
4 × 4 to 6 × 6 in | 1/4–1 in | Chips, sensors, small boards | $1.25–$3.75 each |
8 × 8 to 10 × 10 in | 1/2–1.5 in | Modules and tools | $2.75–$6.50 each |
12 × 12 to 16 × 16 in | 1–2 in | Test gear and kits | $5.50–$14.00 each |
18 × 18 to 24 × 24 in | 1–2 in | Large assemblies | $9.00–$24.00+ each |
These are planning ranges. Foam grade, cut style, depth, volume, and box choice change the quote.
Our MOQ starts at 100 pieces. It suits pilot runs, product launches, replacement packs, and regular supply orders. Custom Boxes Tech reviews product size, box size, quantity, and packing method before we quote.
Order Qty. | Small Insert | Mid-Size Insert | Large/Layered Insert |
100–249 | $1.75–$4.50 | $4.50–$9.50 | $9.50–$22.00 |
250–499 | $1.50–$4.00 | $4.00–$8.50 | $8.50–$19.50 |
500–999 | $1.25–$3.50 | $3.50–$7.50 | $7.50–$17.00 |
1,000+ | $1.00–$3.00 | $3.00–$6.75 | $6.50–$15.00 |
These are estimated U.S. custom-order ranges, not fixed quotes. Higher volume may lower unit cost by about 10%–30% on some layouts when the material and design stay the same.
Many buyers need a carton, lid pad, base pad, or extra part pockets with the insert.
Packaging Setup | Estimated U.S. Price |
Small insert + folding carton | $3.25–$7.50 per set |
Mid-size insert + corrugated box | $6.50–$14.50 per set |
Two-layer insert + corrugated box | $9.00–$19.00 per set |
Large deep insert + shipping box | $14.00–$29.00+ per set |
Extra foam lid pad | $0.60–$3.50 each |
Extra cavity or tool pocket | $0.25–$1.50 each |
CBT can quote in USD for U.S. buyers and prepare project pricing for UK and Canadian orders based on size, freight, and volume.
Electrostatic discharge can harm sensitive electronics, so foam choice needs more thought than color alone. Our team looks at the device, exposed contacts, weight, travel path, and storage use.
For custom ESD foam packaging for sensitive electronics, we can pair the insert with a suitable bag, carton, tote, or case when the full pack needs more protection. Foam alone does not give every product the same level of ESD control.
Our layouts can include CNC-cut foam, die-cut foam, finger notches, relief cuts, cable lanes, stepped cavities, lid pads, and stacked layers.
We size each part to the outer pack so the insert stays in place during normal handling.
Finger notches: often 1/2–1.5 in wide
Foam walls: often 1/4–1 in
Layer builds: commonly 2–4 layers
Depth options: 1/4 in to 2 in+
Sample support: 100% free for eligible custom projects
Design help: 100% free with order setup
Our inserts support boards, processors, relays, drives, meters, connectors, switches, service tools, and lab parts. A set layout also helps staff spot a missing item during packout.
Use custom foam inserts for electronic components when several parts need set positions inside one pack. We can give fragile areas more space and keep heavy parts away from small leads or pins.
The insert needs to fit the outer pack as well as the product. We size the foam around inner box dimensions and lid space.
For custom packaging accessories for electronic kits, our team can add pads, sleeves, dividers, labels, or box parts without crowding the product.
Outer Pack | Common Size Range | Insert Match | U.S. Budget Price |
Small mailer | 4 × 4 × 2 to 8 × 6 × 3 in | Thin PE or PU | $2.50–$6.50 |
Corrugated carton | 8 × 8 × 4 to 16 × 12 × 6 in | Single/layered insert | $6.50–$15.00 |
Large shipper | 18 × 14 × 6 to 24 × 18 × 10 in | Thick layered support | $14.00–$30.00+ |
Reusable case | Product-specific | Multi-cavity layout | $18.00–$45.00+ |
Custom Boxes Tech has worked in packaging since 2002. Our team checks cavity size, part access, foam walls, depth, box fit, and material before production.
CBT also offers a free sample so you can review fit and handling. For projects with a set ESD need, share the target material spec or test method. We will quote the grade that matches it.
Send product size, quantity, photos, CAD files, drawings, or a physical sample.
Our team builds the layout and selects the foam grade.
Review the free sample or design proof and send changes.
We run the approved order with a usual turnaround of 7–12 business days.
For custom foam inserts for PCB shipping, add board size, component height, exposed lead areas, and box dimensions. Those details help us set safer cavity depth and wall space.
Our 24/7 customer care helps with quote updates, repeat orders, size changes, artwork notes, and delivery questions. After-sale service covers project follow-up and future layout updates when your product changes.
Choose strong, precise, and reliable ESD packaging with useful specs, practical pricing, and ongoing support.
Send your files to support@customboxestech.com to find the ideal density of custom ESD foam inserts for your tech gear!
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Serving the packaging industry since 2002
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Quick answers to help you get started with confidence.
Custom Boxes Tech designs every specialized liner to meet strict electronics safety directives. Every production run achieves unmatched compliance because our team maintains tight quality control across these exact metrics:
Surface Resistivity: We maintain this value strictly between 10⁶ and 10⁹ Ohms per square to deliver ultimate dissipative packaging protection.
Material Density Options: Our inventory includes heavy-duty selections from 1.8 lbs to 6.0 lbs per cubic foot to maximize shock absorption.
Compliance Benchmarks: Our protective materials officially pass all structural guidelines of ANSI/ESD S20.20 and JEDEC standard regulations.
Electrostatic Decay Rate: Our
