Foam Engineering: Custom Foam Cutting & Inserts

Trifibre is the leading foam engineering specialist. Our team design and manufacture custom foam inserts in a wide range of sizes and shapes for the interior of hard cases, plastic cases and flight cases. Custom foam cutting can be utilised for any of our cases and padded bags. Using high quality materials and precision, our bespoke foam inserts provide the ultimate protection for your items and are also ideal for product presentation.

Custom Foam Cutting

For our custom foam cutting service, we use a variety of foam types, depending on the size and weight of the items it will contain. Trifibre provides the leading CNC foam cutting service in the UK and we supply a wide range of technical foam materials that are used in a wide range of manufacturing industries. Our knowledgeable team can advise you on the most suitable materials to meet your needs and budget.

In combination with our self-adhesive coatings and comprehensive, custom foam cutting techniques, we are able to supply products in many different forms and provide additional services. This includes tapes, acoustic panels, laminated foam, filtration products, sheets, profiles, embossed, die cut parts, angle cut, CNC routing, gaskets and seals.

Custom Foam Inserts

We can design and manufacture foam parts for our own custom made flight cases, plastic cases and containers, or to fit into any off-the-shelf injection moulded plastic trays or metal stillages.

With 40 years’ experience and the most precise technology on the market, we have vast experience in manufacturing custom foam inserts for a range of applications. Using the highest quality materials, our foam inserts are ideal for supporting and protecting expensive or fragile equipment, from cameras and musical instruments to medical and security equipment. Plus, we can create designs that match your branding.

Based upon the vast experience acquired at Trifibre Ltd, we are now one of the market leaders in CNC foam cutting, with specialist services developed for a range of industries, including the design and manufacture of foam fitments for dunnage and material handling.

Contact us today for a free custom foam cutting quote.

Foam Materials We Work With

Our creative team can design in Solidworks from a wide and unique range of materials, including:

Polyurethane Foam


Egg Box Foam


Polyethylene Foam


Antistatic Foam


Foam disks

Plain or Colour Printed



Protective Packaging

We use state of the art CAD/CAM software for programming our CNC machines. We can also accept customer supplied CAD in all major formats including AutoCAD® DWG, DXF, Solidworks, STP and IGES.

We design and supply cost effective protective packaging for one off or volume products that need protection for that “one way” trip.

From delicate and fragile through to heavy machined parts, we can give you a competitive solution. We can quote from your CAD originated drawings or simply let us have your parts and we will do the rest!

  • LDPE Cross Linked Polyethylene (20kg-240kg/m3)
  • Conductive Cross Linked Polyethylene
  • HDPE Cross Linked Polyethene (from 60kg/m3)
  • Antistatic PE Foam
  • Extruded PE Foam
  • Synergy Recylable Polyethylene (from 33kg/m3)
  • Polyurethane Foam (from 20kg/m3)
  • TriBoard – Class 1, Surface A Protection Dividers

CNC Routing for Foam Engineering, Plywood, Plastic & More

CNC Routing facilities enable us to produce bespoke items with great accuracy to ensure a high-quality production. Trifibre has four state-of-the-art CNC Routers and various other facilities which enables us to complete a number of different projects on time, including our foam engineering services and bespoke routing projects for plywood and plastic.

Our in-house design team use market leading CAD/CAM software for programming our CNC machines. We can also accept customer supplied CAD in all major formats, including Auto CAD® DWG, DXF, Solidworks, STP and IGES.

For more information on our full CNC routing facilities and capabilities, contact our friendly sales team today on 0116 232 3166 or email info@trifibre.co.uk

Foam Inserts

Based upon the vast experience acquired at Trifibre Ltd. we are now one of the market leaders in the design and manufacture of foam fitments for dunnage and material handling.

We can design and manufacture foam parts for our own custom made flight cases and containers, or to fit into any off-the-shelf injection moulded plastic trays or metal stilages.

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Happy customers since 1981...

We’re proud of all the work we do, be it large corporate supply, or a simple box for personal storage. Our decades of experience means we’re the best at what we do.

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