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An ophthalmic device maker learned the hard way what loose-fill does to a sensor housing: three units came back from a distributor with foam beads wedged under an optical window, and each repair meant a full recalibration. The fix was not more tape or more bags. It was molded EPP cushion blocks, cut into the mold as the negative of the part itself.
Shape does the holding. A carved foam pad supports whatever happens to touch it, which is why delicate subassemblies tip and shift in transit. A molded block, by contrast, presents a cavity with walls exactly where the part needs restraint: under a flange, around a boss, against the fragile probe side. The part lifts in and out by hand, yet cannot slide within the cell.
Energy absorption you can point to. EPP crushes progressively and recovers between impacts, so the same block protects through dozens of round trips. Density is tuned to the drop height your distribution plan assumes, not to a generic spec, which is why a 30 g/L block guards a lightweight camera module while a dense 80 g/L block carries a cast pump head.
Spec list:
CB 2530 block: 250 x 300 x 80 mm, 45 g/L EPP, single cavity, 210 g.
CB 4030 pair: 400 x 300 x 100 mm, 60 g/L EPP, lid and base orientation.
CB 6045 set: 600 x 450 x 120 mm, 70 g/L EPP, multi-cavity for kit assembly.
Drop performance: passes 80 cm flat and 60 cm corner drops at rated mass.
Recovery: under 3% thickness loss after 10 compression cycles.
Tooling without the drama. A cavity block starts from the part model and the box inner dimension. TOYOE proposes the cavity layout, molds a sample from production beads, and measures the actual drop result rather than quoting a datasheet. Tool edits for design revisions are routine; the mold stays on file so reorder batches match the validated first article.
If fragile subassemblies are still riding on cut foam, send one part model to TOYOE and we will return a molded cushion proposal with a drop-test plan.
