Skip to main content

Custom is Literally Our Middle Name

Your specs, our craftsmanship. Custom foam products, perfected.

Intricate shapes cut out of foam pieces.
Front facing pieces of layered foam set stacked.
Open black case with tools set into the cutouts.

Do What Only Foam Can 

It’s flexible. It’s durable. It’s precisely what you imagined. 

At Fox, fabricating foam solutions is why we go to work every day. Whether crafting parts for electronics or the marine industry, our skilled designers and next-gen technology will create a foam solution as unique as you and your business.  

Find the Right Foam Fit 

We stock a variety of foam options — and source many more — to ensure you can get what you need for your next custom project. With polyethylene foam in open and closed cell and in many colors and thicknesses, we’ll cut your selected materials to size with the speed and quality you expect from Fox Custom Foam.  

Getting Custom Parts Doesn’t Have to be Hard 

Every Fox project moves from start to finish using our proven DRP method — that’s Design, Refine, Production. It’s simple and smooth. The result is the perfect part.  

previous slide next slide

Identify Tools/Parts

Every project starts with identifying all the items that will be included in your ideal kit.

Not sure where to start? Contact us because we can help with that too.

Scan Each Tool/Part

In order to create the most efficient design, we need to get an accurate picture of each item being kitted.

Share Tool Scans or Photos

Upload your scans to our Portal so we can get started on your kit design.

Questions? Call us at (920) 235-0011.

Select Project Specifications

Let us know any project specifics you have for this kit like whether or not you will be using this foam for tool transport.

If we have any questions, we will contact you within 48 hours.

CAD Design

With your project specifications and tools scans, we’ll get started immediately creating a 3D design file of your foam kitting solution. Or, if you already have one, upload it to our Customer Portal to get started.

Allow up to 1 week processing time for new designs.

previous slide next slide

Select Foam Preferences

You have options for the type of foam used in your project. We’ll make recommendations to go with your design file.

We’re the foam experts so let’s talk.

previous slide next slide

Approve Final Design or Request Prototype

Once the design is approved, we can bring it to life by creating a fully functional prototype if required.

Allow 1-3 weeks production time for prototype creation and shipping. Many projects do not require a prototype to proceed to production.

Approve Prototype, If Required

If opting to fabricate a prototype, we’ll send it directly to you and if you’re happy, we’ll just need a thumbs up to get started with production.

previous slide next slide

Foam Production

With your approval, we are able to enter the production phase of your foam kitting project.

Allow up to 4 weeks production time for most orders. Expedited turnarounds can be handled. Contact us for details.

Order Ships

We are flexible to meet the demands of your timeline and business. We work with you to determine the best way to get your finished products to you.

For local orders, pick-up and local delivery is available. Shipping available throughout the U.S.

Reviews

Quick turnaround and lead times

“We have been very happy with the custom foam shipping cases that we have received from Fox Custom Foam.  The milled foam accuracy and fitment are far superior to other processes such as waterjet cutting.  Quote turnaround and production lead times have been meeting our demands and expectations.  Keep up the good work!”

Luke B.

Custom tooling kits enabled super streamlined processes

“Fox Custom Foam created custom tooling kits for my company and made the process super streamlined. We provided what we needed, and they gave proofs and allowed feedback to get exactly what we wanted. The foam was super durable and fits the tooling beautifully while leaving room to grab the tool easily and keep the tool secure.”

Hannah G.

Why Is Foam Right For Your OEM Parts?  

Polyethylene foam is truly revolutionary. Setting it above rival materials is its flexibility and durability, which enable it to withstand daily wear and tear in most situations. It’s resistant to water, mold and bacteria, making it perfect for marine products, electronics and countless other possibilities. Our skilled designers are foam fabrication fanatics, working with precision and expertise to deliver perfectly crafted parts.

Get the Right Fit For Your OEM Part  

Questions? We’re here for you.

Don’t wait to get make your foam fabrication dreams come true.
Let’s get started on your project today.