Making Foam Lined Boxes For Shipping
Posted 28 September 2007 - 02:48 PM
In the attached photos, I'm using 1/2" extruded foam sheets from the home improvement store. I assemble the box I intend to use and measure the A & C dimension. I then take 1/2" off each dimension and begin the layout on the sheet of foam. I use a "T" square but any straight edge will do. This dimension will be suitable for the top and the bottom so make it easy on yourself and layout the two at once (or all that you'll need).
I then measure the B dimension and subtract the total thickness of two foam pieces combined plus 1/4 to 1/2" depending on overall box dimension (less for very small boxes). Once I have this measurement, I measure the Adimension again and subtract 1/4". I then layout my measurements on the sheet and cut.
Now I use the same modified B dimension used to cut above sheet and measure C dimension. Make sure and subtract the total thickness of two foam pieces combined as you did with the modified B dimension. To save time layout several strips of the B dimension since you'll use this thickness for all side walls of your box.
For square boxes, you can ignore either the A or the C dimension and simply subtract one sheet thickness plus 1/4".
Posted 28 September 2007 - 07:48 PM
Thanks for reading
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