What density of EVA foam is best for packaging?

It depends on the load. 20–40 kg/m³ suits lightweight void fill, 40–60 kg/m³ suits general-purpose protective inserts, and 60–120 kg/m³ suits precision CNC inserts that must hold heavier items like tools or electronics securely in place.

What EVA foam density is right for electronics packaging?

Most electronics cases use 40–80 kg/m³ EVA foam. This range cushions impact without being so dense that it adds unnecessary weight or cost to the shipment.

Can low-density EVA foam protect fragile goods during shipping?

Yes, for lightweight fragile items 20–40 kg/m³ is often sufficient, but heavier or irregularly shaped fragile goods need 60–100 kg/m³ to prevent the foam from compressing under repeated handling.

Does higher density always mean better protection?

No. Higher density increases firmness and shape retention but reduces cushioning for very light items. The right density matches the weight and fragility of the product, not the highest number available.

EVA Foam Packaging Density Guide

Why Density Matters for Packaging

EVA foam density (kg/m³) determines how the foam responds to weight and impact inside a packaging insert. Too low, and the foam compresses permanently under the product's weight, losing its protective shape. Too high, and the foam becomes rigid, adds unnecessary material cost, and can transmit shock instead of absorbing it. For packaging specifically, the right density depends on what's being protected — a smartphone insert and a tool case insert have very different requirements even though both are "packaging foam."

Density Comparison by Packaging Use Case

Density (kg/m³)	Tier	Best-Fit Packaging Applications
20–40	Low	Lightweight void fill, soft wrap inserts, light fragile goods (glassware, ceramics with low mass)
40–60	Medium	General-purpose protective inserts, electronics cases (phones, cameras, small devices)
60–90	Medium-High	Tool cases, instrument cases, items with sharp edges or concentrated point-loads
90–120	High	Precision CNC inserts holding heavy or dense equipment, repeated-use shipping cases

Not sure which density fits your packaging application? Our technical team will recommend a specification.

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Density by Packaging Application

Electronics Packaging

Electronics inserts typically use 40–80 kg/m³. This range cushions impact during transit without adding excess weight or cost to the shipment. CNC-cut cavities at this density hold the device firmly while absorbing drops and vibration during handling.

Tool and Instrument Cases

Tools and instruments often have sharp edges, uneven weight distribution and repeated insertion/removal cycles. A density of 60–90 kg/m³ resists compression set and tearing better than lower densities, keeping the cut cavity shape over years of use.

Fragile Goods

Lightweight fragile items (glass ornaments, ceramics, light electronics components) are well protected at 20–40 kg/m³, where the foam's softness absorbs shock without needing to support significant weight. Heavier fragile goods need 60–100 kg/m³ so the foam doesn't compress flat under sustained load.

Shipping and Transit Inserts

For repeated-use shipping cases and pallet-level protection, 60–120 kg/m³ is standard. These inserts need to survive multiple shipping cycles without losing their shape, so higher density and better compression-set resistance matter more than in single-use packaging.

How to Request the Right Specification

When requesting a quote, provide: the item being packaged (weight, dimensions, fragility), whether the insert is single-use or repeated-use, and any existing sample or competitor reference. Our technical team will recommend the density and cutting pattern based on your application.

Need custom CNC-cut packaging foam? Request a sample in your target density.

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How to Choose EVA Foam Density for Packaging