Convoluted Foam Offers Smart, Customizable Protection for Packaging And Cases

Although flat foam inserts and die-cut components are widely recognized, convoluted foam stands out as one of the most versatile and visually distinctive options available.
Often referred to as egg crate foam, it offers outstanding cushioning and adaptable product containment while remaining lightweight and cost-effective. This makes it ideal for a broad range of applications, including custom case inserts and beyond.

What Is Convoluted Foam?

Convoluted foam is a flexible cushioning material featuring a wave-like, or“egg crate,”surface pattern. The alternating peaks and valleys create a three-dimensional structure that compresses under pressure and recovers when released, providing an effective combination of cushioning, airflow, and shock absorption.

This contoured design enhances protection and allows for a more adaptable fit, making convoluted foam a popular choice for packaging items such as electronics, tools, medical devices, and military equipment.

How Is Convoluted Foam Made?

The characteristic pattern is produced by contour-cutting foam sheets using a specialized profile-cutting blade or roller press. Often, a single foam bun is cut to form two interlocking convoluted sheets, which can then be used as matching top and bottom layers inside a case or container.

Convoluted foam can be manufactured from several foam types to meet specific performance requirements, including:

●Polyurethane (PU) – Soft, flexible, and highly compressible

●Polyethylene (PE) – Closed-cell, semi-rigid, and resistant to moisture

●Cross-linked Polyethylene (XLPE) – Durable, smooth-surfaced, and chemically resistant

At TOPSUN Foam, we offer convoluted foam in a wide variety of densities, thicknesses, and material options to deliver the level of protection and customization your application requires.

Where Is Convoluted Foam Used?

Convoluted foam is widely utilized in industries that require gentle cushioning, vibration control, and surface protection during shipping, handling, or storage. Key applications include:

Protective Case Interiors

Commonly used in hard-shell cases to secure sensitive equipment. The contoured foam helps limit movement and provides reliable impact absorption.

Product Packaging

Ideal for premium packaging where appearance and protection matter. Frequently used for electronics, collectibles, medical devices, and other high-value items.

Electronics and Instrument Protection

Offers non-abrasive cushioning for delicate components such as circuit boards, sensors, and precision instruments.

Medical and Laboratory Equipment

Provides stable, contaminant-free support for delicate tools and devices during transport or storage.

Military and Tactical Gear

Used in cases for firearms, optics, and other mission-critical equipment thanks to its ability to secure items firmly and withstand impact.

Convoluted Foam Provides Enhanced Protection for Your Products

The strength of convoluted foam lies in its engineered geometry. Its distinctive peaks and valleys create differential cushioning, allowing the foam to gently cradle irregular shapes while maintaining consistent, even support. Here’s how this design benefits case and packaging applications:

Gentle Surface Contact

The contoured pattern limits the amount of foam directly touching the product, reducing friction and minimizing the risk of scratches—ideal for polished surfaces, coated components, or lenses.

Adaptive Fit for Complex Shapes

The foam naturally conforms to items with varied dimensions or protruding features, often eliminating the need for precise cutouts.

Impact and Vibration Protection

Its compress-and-recover behavior absorbs shock and dissipates energy from drops, bumps, and mechanical vibration, helping prevent damage during handling or transit.

Improved Airflow and Breathability

The open structure encourages air circulation, supporting heat dissipation and helping reduce condensation inside sealed cases.

Lightweight Efficiency

By using less material than flat foam, convoluted foam remains lightweight while still delivering reliable protection—an advantage for both portability and shipping costs.

Customizing Convoluted Foam for Your Product

At TOPSUN Foam, we design and manufacture tailored foam packaging solutions, including customized convoluted foam for a wide variety of cases and applications.

Whether you need inserts for hard-shell cases, retail displays, or bulk shipping containers, we can engineer convoluted foam to meet your product requirements and align with your brand standards.

Our team guides you through a straightforward customization process:

Select the Right Material

We help you choose the ideal foam type based on your performance, aesthetic, and compliance needs.

Optimize Thickness and Density

Thicker foam with deeper contours offers greater shock absorption, while density determines softness or firmness. We assist in selecting the best combination for your application.

Precision Sizing and Fabrication

If you need foam that fits a specific case or container, we fabricate it to exact dimensions using our in-house contour cutting, die cutting, and lamination capabilities.

A Protective and Cost-Effective Foam Solution

Convoluted foam is an excellent choice when you need lightweight protection, reliable cushioning, and a visually appealing presentation. Its ability to conform to diverse shapes, absorb impact, and scale to custom applications makes it a trusted option across many industries.

Ready to enhance your packaging or case interiors? We can create a custom convoluted foam solution that provides the protection your products deserve.