Precision Laser Cut Foam Box Insert

Custom Laser Cut Foam Inserts for Premium Presentation Boxes

Many of our laser cutting projects involve the design and manufacture of precision-cut foam inserts for luxury presentation boxes. These bespoke foam inserts are created to securely hold products in place while enhancing the overall presentation, making them ideal for premium gift sets, product launches, corporate gifting, influencer campaigns, and retail displays.

Over the years, we have produced custom laser cut foam inserts for many well-known brands, including Hendrick’s Gin, Grey Goose, Johnnie Walker, Guinness, Coca-Cola, and a wide range of luxury perfume and cosmetics companies. Every insert is designed specifically for the products it will hold, ensuring a perfect fit and a premium unboxing experience.

Each project begins by receiving either the presentation box itself or detailed dimensions of the box, along with the products that will be displayed inside. Our team carefully measures every item to create accurate CAD drawings of each component. This process allows us to design a layout that maximises presentation while ensuring every product is held securely during transport and handling.

Once the layout has been approved, we produce detailed CAD files for each layer of foam. Depending on the size, shape, and depth of the products, the insert may consist of multiple layers of EVA foam, each precision laser cut to create perfectly recessed cavities. This layered construction provides excellent protection while delivering the clean, professional appearance expected from luxury packaging.

Our CO₂ laser cutting process produces exceptionally clean edges and highly accurate profiles, making it ideal for premium packaging applications. Whether manufacturing a single prototype or a large production run, every foam insert is produced to the same exacting standards.

Custom laser cut foam inserts are suitable for a wide variety of products, including premium spirits, perfumes, cosmetics, electronics, medical devices, promotional products, awards, jewellery, tools, and corporate gifts. Available in a range of foam densities, colours, and thicknesses, every insert is tailored to suit the specific product and presentation box.

Our combination of precision CAD design, laser cutting expertise, and attention to detail ensures every foam insert delivers outstanding protection while creating a memorable presentation that reflects the quality of your brand.

Features

• Bespoke laser cut EVA foam inserts
• Precision CAD-designed layouts
• Custom fit for products of any shape or size
• Multi-layer foam construction for added protection
• Suitable for luxury presentation boxes and gift packaging
• Clean, accurate laser-cut edges
• Prototype and production manufacturing
• Available in multiple foam densities, colours, and thicknesses
• Designed and manufactured in-house
• Ideal for corporate gifts, retail packaging, and promotional campaigns