Foam Engineering: Customised Foam Cutting and Inserting

Trifibre is the leading specialist in foam engineering. Our team designs and manufactures customised foam inserts in a wide variety of sizes and shapes for the interior of rigid suitcases, plastic bags and flight cases. The customised foam cut can be used in any of our suitcases and padded bags. Using high quality, precision materials, our customised foam inserts offer maximum protection for your items and are also ideal for product presentation.

Personalised Foam Cutting

For our customised 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 UK's leading CNC foam cutting service and we supply a wide range of technical foam materials that are used in a wide variety of manufacturing industries. Our experienced team can advise you on the most suitable materials to suit your needs and budget.

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

Customised foam inserts

We can design and manufacture foam parts for our own flight cases, plastic bags and containers or to fit any injection-moulded plastic tray or metal shelving available on the market.

With 40 years' experience and the most precise technology on the market, we have extensive experience in manufacturing customised foam inserts for a variety 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. What's more, we can create designs that match your brand.

Based on the vast experience gained at Trifibre Ltd, we are now one of the market leaders in CNC foam cutting, with specialised services developed for a variety of industries, including the design and manufacture of foam accessories for material handling and premieres.

Contact us today for a free personalised foam cutting quote.

Foam Materials We Work With

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

Polyurethane foam


Egg Crate Acoustic Foam


Polyethylene foam


Anti-static foam


Plain or Printed in Colour



Protective packaging

We use state-of-the-art CAD/CAM software to programme 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 economical protective packaging for single or large-volume products that need protection for that "one-way" journey.

From delicate and fragile parts to heavy machined parts, we can offer you a competitive solution. We can give you a quote based on your CAD drawings or simply leave us your parts and we'll do the rest!

  • LDPE cross-linked polyethylene (20kg-240kg/m3)
  • Conductive cross-linked polyethylene
  • HDPE cross-linked polyethylene (from 60 kg/m3)
  • Anti-static PE foam
  • Extruded PE foam
  • Synergy recyclable polyethylene (from 33kg/m3)
  • Polyurethane foam (from 20kg/m3)
  • TriBoard - Surface Protection Dividers A, class 1

CNC Routing for Engineered Foam, Plywood, Plastics and More

The CNC routing facilities allow us to produce customised items with great precision to guarantee high-quality production. Trifibre has four state-of-the-art CNC routers and several other facilities that allow us to complete many different projects on time, including our foam engineering services and customised routing projects for plywood and plastic.

Our in-house design team uses market-leading CAD/CAM software to programme 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 about our facilities and complete CNC routing capabilities, contact our sales team today on 0116 232 3166 or send an e-mail to [email protected]

Foam inserts

Based on the vast experience gained at Trifibre Ltd., we are now one of the market leaders in the design and manufacture of foam accessories for drainage and material handling installations.

We can design and manufacture foam parts for our own suitcases and custom flight cases, or to fit into any injection-moulded plastic tray or ready-made metal frame.

Get in touch

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