High quality custom eva foam plug-in packaging and kits are used to protect packaged products

Good evening, everyone. Today, a military customer from the 722 Research Institute, which works on shipbuilding, gave feedback that the previous milled EVA foam was too heavy. This caused high costs in transportation, handling, and other aspects, and made it difficult to transport. They asked if we had any alternative solutions. As an EVA foam manufacturer, I’d like to share some ideas with you:

1. EVA foam is a type of foamed material, and its typical density is 38 degrees, though there are also 50 degrees, 60 degrees, etc. The higher the density, the heavier it is, and of course, the more expensive it becomes. There’s also high-elasticity 25-degree foam, which has better elasticity but costs about twice the price of regular 38-degree foam. However, the overall weight difference is not significant, so using EVA foam alone for milling won’t reduce the weight by much.

2. A recommended solution is to use a bonding approach. First, use a high-density foamed material for the bottom. This type of material is much lighter, but it requires a higher level of skill from the craftsmen because there are different densities of this material, and only the higher-density variants are suitable for milling. Then, you can bond a 5mm layer of EVA foam on top, which not only reduces the weight but also gives a more premium look. However, sourcing materials can be more complicated, as it often requires a minimum order quantity.

3. Another approach is to use EPE foam material for the bottom, and also bond a layer of EVA foam on top. This solution reduces the weight significantly. However, EPE foam doesn’t look as nice; it tends to have a lower-end appearance, though it is easier to source. But this also comes with its own challenges. EPE has a relatively low density, so the milling tool needs to move slower during processing. Additionally, after the milling, a special procedure is needed to blow dry the back, allowing the EPE foam to shrink uniformly. EPE is also much cheaper, but it does require an additional bonding step, where the EPE’s adhesive backing is attached to a 5mm EVA layer before milling or carving to create the finished product.

As you can see in the following products, the bottom layer is made of EPE or high-foam materials, and the top layer is made of colored or black EVA material. This approach not only improves the appearance but also addresses the issue of EVA foam being too heavy.