At SmartShield, we speak to a lot of customers who start with the same question: Is pick-n-pluck foam good enough to package our equipment - or is it time for something more precise?
Choosing the right industrial foam packaging isn’t always straightforward, especially when your products need to arrive exactly as they left, every single time. Whether you’re transporting tools, or high-value components, foam packaging plays a critical role in protecting what matters most.
Many businesses start with pick-n-pluck foam because it’s quick, affordable, and easy to use. But as products become more valuable, shipments more frequent, or presentation more important, it’s worth taking a step back and reassessing.
So, should you stick with pick-n-pluck foam, or switch to a custom-designed perforated, modular solution, or a fully customized foam insert? All three options offer protection, but they’re designed for very different levels of precision, durability, and performance. To understand the difference, it helps to start with what pick-n-pluck foam is, and where it works best.
Pick-n-pluck foam (also known as cubed foam) is pre-scored into small cubes that can be removed by hand to roughly match the shape of your product.
When pick-n-pluck foam works well:
For basic protection or short-term use, pick-n-pluck foam can be a convenient starting point.
However, its flexibility is also its biggest limitation.
While pick-n-pluck foam is easy to customise, it is a time-consuming process to remove the necessary sections of foam. More importantly it lacks the structural strength and precision needed for more demanding applications.
Because the foam is perforated, its structure is weakened from the start. Over time, cubes can loosen, tear, or compress, especially with repeated use, vibration, or heavy components.
This can lead to:
For products that need reliable, repeatable protection, this is where modular or fully custom foam become the smarter long-term choice.
Perforated modular foam solutions lie between Pick-n-Pluck and fully customized foam sets, they can be engineered to fit plastic cases or corrugated cartons with pre-cut perforations that allow sections to be easily removed to accommodate a variety of components. While this option does not provide the exact, snug fit of a fully custom-cut insert, designed for a specific item, modular foam offers a higher level of protection than Pick-n-Pluck or cubed foam. It also allows for faster customization and delivers a cleaner, more professional appearance.
Custom foam inserts are a key part of effective custom packaging and are designed specifically around your product, your case or carton, and your real-world use conditions.
Rather than adapting your packaging around generic foam, custom foam is engineered to fit perfectly - every time.
Each component has a dedicated pocket, designed to support it properly and reduce movement, shock, and vibration during transport.
Custom foam delivers a clean, polished look that reflects the quality of your product — ideal for customer deliveries, demos, and trade shows.
With everything clearly laid out, packing becomes quicker and more consistent. There’s no guesswork, every item has its place.
Unlike pick-n-pluck foam, modular foam provides a more structured middle-tier solution, while fully customized foam options retain their structural integrity, making it far more durable for repeated use.
Custom inserts are ideal for ongoing shipments, service kits, or returnable transit packaging where durability really matters.
Custom foam can combine different densities and materials to meet specific requirements, including:
Designers can optimise the layout to reduce wasted space, allowing for smaller cases or cartons, which can significantly cut shipping costs.
Pick-n-pluck foam is a good option if:
Modular foam inserts are ideal for:
Custom foam inserts are the better choice when:
At SmartShield, we design custom packaging solutions that go beyond protection, helping businesses improve efficiency, reduce damage, and present their products properly.
If you’re unsure whether pick-n-pluck foam is still right for your application, or you’re ready to upgrade to a modular or fully custom solution, get in touch with our team to discuss your packaging needs today.