I plan on making foam box inserts to hold/protect products. The products are laser cut acrylic parts and the foam is only 10-12mm thick.
The issue I have is the edge of the laser cut foam leaves residue on the product. Not immediately, and not a lot but after shipping to the customer, all the movement and vibrations could make the product a little dirty.
I’ve tried EVA, PE and EPE foam so far and the ideal foam is hard EVA. EPE (expanded PE) doesn’t seem to leave residue at all - but it’s far too soft.
So am I doing something wrong or is this unavoidable?
I haven’t tried PU based open cell foam yet. That stuff is probably too squishy (like EPE) though, as i’m after more rigid cushioning.