Foam cutting technology and machinery at MSA Foams

We utilise an 8-person design team with a vast amount of experience and knowledge in packaging and industry - two of which are qualified in the MPAS (Military Packager Accreditation Scheme), which is a very select and important addition to our qualifications. Using the software and technology outlined below, MSA Foams can deal with almost any type of design enquiry and cater to all customers, from individuals to corporations.

A CNC machine cutting into a piece of foam at MSA Foams.

3D scanning technology

We use 3D scanning technology to create a 3D model of your item, using its shape and orientation to create a bespoke protective solution.

Farro scanner

The Faro Edge is an articulated arm with 3D scanner that records the profiles of an item in 3D space. The result is a complete 3D representation/surface model of the physical item. This gives the designer all the information they need to house an item within the packaging solution.

A man using the Faro Edge 3D scanner to scan a camera.

Leo scanner

The Leo scanner is a handheld, mobile scanner. This portable system allows our Nationwide team of consultants to visit the customer on site. The Leo utilises wireless technology,  allowing more freedom to manoeuvre around larger items and capture data more easily.

a hand holding the Leo remote 3D scanner.

Extensive design software

Our 8-person design team uses the best software in the business to design a protective foam solution for almost any design enquiry.


ALPHACAM is the main CADCAM software we use for design, CNC machine tool pathing and creating the production instructions for manufacture.


SOLIDWORKS® is a 3D package that enables us to check design elements visually as well as technically. 3D views on drawings also means that customers can easily see the intended design.


CATIA V5 is a high-end 3D CAD software, widely used in larger automotive, aerospace, and high-end engineering industries. Being able to open native CATIA CAD and design files saves a lot of time, prevents issues and makes an easy flow of data from customer to design.

Two computer monitors displaying CADCAM software used at MSA Foams


Our 32,000 sq. ft. manufacturing facility is home to a number of our advanced foam conversion machines.


The prep department is where raw material is converted into accurate blocks ready for CNC  machining. Machinery in this department includes:

  • Fecken Kerfal and Baumer flatbed slitters for slicing raw material.
  • Heat laminator to laminate foam together using heat to create blocks to the depth required.
  • Hyma bandsaws cut laminated sheets into blocks for CNC machines.
A block of hot pink foam being prepared on a flatbed slitter.

Foam conversion machinery

  • 8 x CNC routers convert the foam block into pre-designed fittings. Pockets are cut to shape and varying depths to suit the project at hand.
  • Dual-head waterjet uses 5 axis for fast cutting and shaping foam.
  • Die-cutter is an economical method of converting foam where volume is required. Once tooling is in place, cutting can be completed within seconds.
CNC foam conversion machinery

Printing & engraving

  • Our digital printer can print your corporate identity directly onto your case or container.
  • The digital printer cutter produces labels and stickers to further enhance the aesthetic of the case or container.
  • 2 x laser engraving machines engrave the foam allowing for corporate identity or pocket identification. These machines also have the capability to engrave labels, information plates and nameplates.
A laser engraving machine engraving the MSA Foams logo into a piece of foam.


Skilled workers assemble and create final shaping using a series of band saws, routers and hand tools to ensure foam fits the container correctly before passing to final QA inspection.

A custom foam insert being cleaned with an air tool during the finishing process.