Materials We Work With

Open cardboard box containing white PE foam packaging materials, including a large piece with a cutout and smaller foam pieces.

Polyethylene (PE) Foam

Polyethylene (PE) foam is a lightweight, durable, closed-cell foam known for its excellent shock absorption, moisture resistance, and cost effective performance.

PE foam is also versatile. Being offered in multiple densities, with antistatic properties, and high recycled content, we are able to find a foam to fit a wide range of our customers’ needs.

Die cut honeycomb endcap with a partial cut and crush.

Expanded Polyethylene (EPE) Foam

Expanded polyethylene (EPE) foam is a lightweight, closed-cell foam made by expanding polyethylene beads and fusing them together using steam. While being a step up in shock absorption from regular PE above, EPE also adds abrasion resistance; making it a perfect option to pack parts with Class-A surfaces. Offered in a wide range of densities as well as conductive properties, EPE has superior cushioning properties along with abrasion resistance on Class-A surfaces.

Close-up of a corrugated fiberboard, showing the detailed, layered corrugated cardboard material.

Corrugated Plastic

In the world of returnable packaging, corrugated plastic is a durable option. Offered in multiple different thicknesses, with class-A surface protecting spunbond coatings, and with conductive properties, Pac Basic can convert the correct material for your needs.

DECKED Piecekeeper PuzzleFoam.

Honeycomb

Honeycomb is a durable, eco-friendly packaging material made from kraft paper arranged in a hexagonal cell structure. If you’re looking for maximum stacking strength, or cushioning with sustainability, honeycomb could be the perfect solution. Honeycomb works well for blocking and bracing, die cutting, cushioned endcaps, and filling.

Expanded Polyethylene EPE foam die cut rails for packaging.

Corrugated fiberboard

While you may have multiple corrugated boxes show up at your front door every week, not all of them are created equal. Between Mullen and ECT board grades, finding the right box style for you, and finding a suppllier that won’t make you purchase a large MOQ, Pac Basic is able to help you navigate the world of corrugated boxes. We have in-house production and printing capabilities, state of the art design and sampling equipment, and partners that run many thousands of boxes a day. Know that no matter your scale, you’ll be in good hands with the Pac Basic team.

Utilizing our design software and experience, our engineering team is also able to help out with complicated die cuts and inserts, giving you a 3D model of your part in packaging before pulling the trigger on tooling.

A black bulk crate with plastic corrugated partitions.

Crosslinked PE (XLPE) Foam

Crosslinked PE foam (XLPE) is another tool in Pac Basic’s toolbelt as a premium option for returnable/reusable packaging as well as finished goods. Matching EPE above in impact and abrasion resistance, XLPE offers a step up in durability.

XLPE also has a great presentation for finished goods! We’ve partnered with SEKISUI Voltek and their VolaraBLOCK to create the DECKED Piecekeeper PuzzleFoam™, a system of friction-fit foam pieces that lets you create custom storage compartments in just about any shape or size.