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Heavy parts rarely arrive damaged from one big drop; they arrive marked from hundreds of small ones. A casting that rides on a flat foam pad presses a crater into it on the first trip, and by the tenth cycle the pad holds a permanent dent and the part begins to shift. The liners in this programme attack that problem at the root: every kilogram is carried by a shaped cavity instead of a flat surface.
Spreading the load across shaped contact
Each cavity is modelled around the actual casting, following bosses, flanges and draft angles. Broad pads carry the part on its machined faces while filler ribs take up the slack around irregular contours, which typically doubles the effective contact area compared with hand-cut foam. Lower contact pressure means no dented mounting faces, fewer rubbed surfaces and far less deburring and rework at goods-in.
Recovery that survives the shuttle loop
Fused-bead EPP recovers more than 95 percent of its thickness after each compression cycle, so a liner keeps its cavity geometry across thousands of collection runs. Where urethane foam goes flat and chip foam sheds, this material simply returns to height; a mark left by a hard knock springs back within minutes instead of becoming permanent.
Standard liner platforms
LS 1210-H: 1200 x 1000 mm footprint, 160 mm cavity depth, two-part set, payload 120 kg, density 60 kg/m3.
LS 1210-M: 1200 x 1000 mm footprint, 110 mm cavity depth, payload 60 kg, density 45 kg/m3.
LS 865: 860 x 650 mm footprint, 120 mm cavity depth, payload 40 kg, density 45 kg/m3.
LS 604: 600 x 400 mm footprint, 90 mm cavity depth, payload 15 kg, density 30 kg/m3.
Stable in the real plant environment
The foam stays elastic from -40 C to +130 C, so liners behave the same in a winter yard and beside a heat-treatment line. Water absorption stays below 0.3 percent even through condensation cycles, oils and cutting fluids do not attack the surface, and every grade can be issued with REACH and ROHS declarations for your audit file.
From sample to series
Send drawings, a 3D scan or the part itself. We model the cavities, cut a CNC-machined prototype for a fit trial, then move to a moulded production tool once the fit is confirmed. Revisions are cut into the existing mould, so running changes on the casting do not restart the programme.
Share your heaviest part and its annual volume, and our engineers will return a load-spreading cavity proposal with a contact-area calculation, density recommendation and tooling cost within three working days.
