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Foam blocks prove a simple solution to sticky case problem

Custom case with foam adhesive

A customer approached to us because they’d been facing significant installation challenges with foamsets for their cases. Their existing vendor applied an adhesive glue as part of the foam assembly process, using it to affix the foamsets to the case.

Solution

On the one hand, when the adhesive was under-applied, the foam would separate from the case. On the other, when too much was applied adhesive wicking and bleed-through would occur.

Both issues with adhesive compromised case presentation and had a significant effect on the customer’s operations. If the interior cavities contained glue or if the foam detached from the case, their end customers would reject the product. Worse, it rendered the entire foam insert unusable: repairs were impossible.
This meant the customer needed to invest extra resources in replacing faulty products, increasing costs and incurring delays in customer orders.

Additionally, the adhesive’s curing time increased labor costs and prolonged production because of the need for additional manual inspection.

To address these challenges, we proposed incorporating foam blocks into the top and bottom foam inserts. These blocks would serve as secure locks, ensuring that the inserts remained firmly in place within the case and entirely removed the need for adhesive glue.

Outcome

The implementation of foam blocks yielded immediate improvements.

With the foam blocks securely holding the inserts in place, the issue of foam detachment was completely resolved. The elimination of adhesive inside the case cavity not only improved the presentation, it also eliminated the risk of rejection by end customers due to the presence of glue.

Additionally, the use of foam blocks reduced labor time, as there was no longer an adhesive application and curing step. This increased overall production efficiency and reduced costs associated with inspection and rework.

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