We cut EVA foam from flat sheets for case inserts, packaging, seals, pads and protective components. Digital knife, CNC and laser (where appropriate) for EVA foam sheets up to 3000mm x 1500mm – tuned for clean edges, accurate profiles and repeatable nesting.
EVA foam is a go-to material when you need lightweight cushioning, impact protection, good appearance and the option for colour coding. We mostly cut EVA foam for:
EVA foam is a closed-cell material with a smooth finish and good impact resistance. It behaves very differently to rigid plastics or metals: it compresses under the blade, can stretch if pulled and edges need to be supported. We set cutting method, tooling and parameters specifically for EVA foam density and thickness.
For most EVA foam projects we favour digital knife cutting – it produces a crisp, square edge without heat-affected zones.
We can work from CAD files, traced outlines, measured sketches or existing foam inserts that need to be replicated or updated.
Our goal is to deliver EVA foam parts in logical sets, ready to drop into cases, trays, panels or assemblies without re-sorting.
EVA foam behaves differently to rigid sheet materials. Our cutting workflow – tooling choice, feed rates and vacuum hold-down – is built around keeping edges crisp while avoiding over-compression or stretching.
We design and nest EVA foam parts with real use in mind: gear has to be protected, easy to see and fast to check in and out. That drives decisions on depth, clearances and how pieces are grouped.
EVA foam is often paired with plastics, metals and printed panels. Because we cut all of these in-house, we can help align allowances and tolerances across the full kit.
We regularly work as a behind-the-scenes cutting partner for OEMs, case makers and fabricators. Clear communication, predictable turnaround and stable pricing for repeat kits are the priority.
Get instant prices for laser-cut and CNC-cut parts across metals, plastics, composites and more — available 24/7.
Launch the calculator to upload DXF, DWG or vector files and see live pricing for flat laser-cut parts. Pricing updates instantly based on material, thickness and cut time.
Open instant calculatorAccepted formats: DXF / DWG / AI / SVG / PDF (vector).
Send measurements, sketches or existing parts and we’ll create cut-ready drawings, then quote via the same engine.
Simple plates and brackets can often be drawn and quoted the same day.
EVA foam is a go-to material when you need lightweight cushioning, impact protection, good appearance and the option for colour coding. We mostly cut EVA foam for a wide range of protective and practical applications.
Our EVA foam cutting service in Sydney is set up for precision cutting across multiple foam densities and thicknesses. Whether you need protective case inserts, retail packaging, or industrial component kitting, we can cut EVA foam to exact specifications.
Typical applications include tool control foam, protective case inserts, equipment packaging, retail presentation boxes, component kitting, gaskets and seals, and display builds. We work with manufacturers, distributors, OEMs and packaging companies across all industries.
For EVA foam cutting that protects your products and enhances your brand presentation, upload your files or contact us to discuss material options and design requirements for your next foam project.
EVA Foam Cutting in Sydney. Laser Cutting Experts Offers High-Precision EVA Foam Cutting Services in Sydney Australia.
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