Custom ESD Packaging Foam & Surface Protection Film for Electronics
H-O Products die-cuts and converts conductive and static-dissipative polyethylene (PE) foam, cross-linked PE and expanded polyethylene (EPE), low-tack surface-protection film, PVC cling, UHMW-PE liner, and pressed felt into the ESD-safe cavity inserts, trays, interleaving, dunnage, protective liners, and temporary surface films that carry a board, module, or finished housing between processes and through shipment, built to your drawing.
Built for: ESD-safe cushion inserts and trays for boards and modules, interleaving and dunnage, temporary low-tack surface-protection film for displays and painted or anodized housings, protective liners during assembly, moisture-barrier and static-shielding bag context, and reusable tote inserts — classified by surface-resistance class per ANSI/ESD S541 and measured per ANSI/ESD STM11.11 on the vendor TDS.
To specify ESD-safe packaging, classify the part by its surface-resistance class first, then pick the family. Conductive cushioning (< 1.0 × 10⁴ Ω per ANSI/ESD S541-2019): conductive cross-linked polyethylene foam (typically black), die-cut into cavity inserts and trays for the fastest controlled charge bleed. Static-dissipative cushioning and the remaining classes are mapped in the When-to-spec list on this page. Values are per the TDS on file; see the material reference below for ordering details.
System / program-level, by designation (conformance belongs to the qualified program or bag system): ANSI/ESD S20.20-2021 (ESD-control program) · ANSI/ESD STM11.31-2018 (bag discharge-shielding, energy penetration) · MIL-PRF-81705F (flexible barrier materials; Type I / Type III).
Material / packaging-level, per the maker TDS: ANSI/ESD S541-2019 (resistance-class definitions) · ANSI/ESD STM11.11-2022 (dissipative surface resistance) · ASTM D257 (insulative resistance) · ASTM D3330 (peel adhesion) · ASTM F1249 (water-vapor transmission) · UL 94 (flammability on rated grades).
- Conductive cavity inserts / trays: cross-linked PE foam
- Dissipative interleaving / dunnage: expanded polyethylene
- Die-cut clip / retention inserts: ClipFoam (by density)
- Display / housing surface protection (adhesive): PolyMask PE film / protective films
- Adhesive-free cling protection: PVC cling
- Fixture slip / wear liners: UHMW-PE liner / pressed felt
- Grounding-contact sponge: conductive sponge
- Moisture-barrier context (films/laminates): films, papers & laminates
This guide is for packaging, ESD-control, and manufacturing engineers, and the sourcing buyers who support them, specifying ESD-safe cushion inserts and trays, interleaving and dunnage, temporary surface-protection film, assembly liners, and reusable tote inserts for electronic and IoT products that must be handled and shipped under a defined ESD-control program (ANSI/ESD S20.20) with packaging classified per ANSI/ESD S541.
Where are you in the packaging spec?
This page serves engineers who already know the foam class and film they want and engineers still assembling the protection kit requirement by requirement. Pick the path that matches where you are; you don't have to read the rest.
Send a drawing, get a quote
A conductive or dissipative PE-foam cavity insert, an interleaving or dunnage set, a low-tack surface-protection film, a reusable tote insert, or a complete protection kit on your drawing, with the surface-resistance class and the finish to be protected noted.
Skip to the quote form →Build the protection kit requirement by requirement
Six selection factors (resistance class, cushioning duty, film tack and exposure, moisture/shielding context, reuse, kitting), an ESD-packaging stack builder, and the material families with S541 classes and STM11.11 methods cited on the TDS.
Start with selection factors →
Resistance class → cushioning & handling case → surface protection → moisture/shielding context → to drawing → production supply.
- 1Set the resistance classConductive or dissipative per ANSI/ESD S541, measured per STM11.11 on the TDS.
- 2Size the cushionFoam density and cavity depth to the drop/handling case, not just the part footprint.
- 3Match surface protectionFilm peel adhesion and exposure window to the finish being covered.
- 4Add moisture / shielding contextBarrier-bag and shielding requirements by designation at the system level.
- 5Die-cut to drawingCavity inserts, interleaving, film, and liners die-cut, kiss-cut, or slit to the part.
- 6Quote prototype or productionSamples, then production with material traceability and lot-code TDS records.
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1Send drawingUpload a DXF, STEP, or PDF, or describe the part, the surface-resistance class target, and the handling case. A sample part works too.
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2Material reviewEngineering reviews the resistance class, cushioning duty, film tack and exposure, and any moisture/shielding requirement against the grade TDSs, and frames the standards language correctly: resistance classes per ANSI/ESD S541 (measured per STM11.11) by TDS; program and bag-system standards (ANSI/ESD S20.20, STM11.31, MIL-PRF-81705) by designation, at the system level.
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3PrototypeSamples typically ship in 3–5 business days for common configurations in materials we commonly convert. Made-to-order; MOQ varies by material and part.
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4ProductionStandard production runs ship about 2 weeks after drawing approval, on flatbed die-cutting, CNC knife cutting for kiss-cut insert and film sets, and kitting for full per-unit protection kits. Ongoing parts run with material traceability and lot-code TDS records.
Which protection part are you specifying?
Application Zones
ESD-safe packaging is not one part; it is a layered set of single-purpose protections between processes and in transit, each with its own controlling property. Die-cut PE-foam cavity inserts cushion and locate boards and modules; interleaving and dunnage separate stacked parts; temporary surface-protection film covers finished displays and housings; assembly liners protect fixtures and work surfaces; the moisture-barrier and static-shielding bag surrounds the whole kit; and reusable tote inserts carry parts through internal WIP flow.
Click a tab to see the part, the controlling properties, and the families H-O converts for that zone. Program conformance (ANSI/ESD S20.20) and bag shielding/moisture performance belong to the qualified system; every zone below is a converted part that supports it.
ESD-safe cushion inserts & trays: the cavity that cradles the part
The core converted part is the PE-foam cavity: pockets routed or to the part outline that both locate a board or module and cushion it against drop and handling shock. Two decisions govern it.
First, the surface-resistance class per ANSI/ESD S541-2019: conductive foam (typically black, surface resistance < 1.0 x 104 Ω) for the fastest controlled charge bleed, or static-dissipative foam (1.0 x 104 to < 1.0 x 1011 Ω) where a slower, controlled decay is acceptable; the class is measured per ANSI/ESD STM11.11-2022 on the vendor TDS and characterized at 12% and 50% RH because many antistatic treatments are humidity-dependent.
Second, the cushioning duty: cross-linked polyethylene (XLPE) foam has finer, more uniform closed cells and better durability for reusable inserts, while expanded polyethylene (EPE) is the economical single-trip choice. Size the foam density and cavity depth to the drop/handling case, not just the footprint. [2]
Interleaving & dunnage: separating and blocking stacked parts
Between the cavity insert and the shipper sit the parts that keep stacked assemblies from touching each other and from moving in the box: thin interleaving sheets between boards, spacer pads, and block-and-brace dunnage that fills void and locates a heavy assembly. For ESD-sensitive parts these are dissipative by construction, not insulative, so an interleaving sheet does not become a charge generator itself.
Expanded polyethylene is the workhorse here — light, cushioning, and available in antistatic grades — into sheets, pads, and profiled dunnage to the packing drawing. The rule is the same as the cavity: the material's surface-resistance class (per S541) is a spec, not a color, and the piece has to cover the contact area without becoming the tallest thing in the box.
Send the stack-up and the void map, and the interleaving and dunnage fall out of the layout. [2]
Temporary surface-protection film: covering displays & finished housings
Displays, painted or anodized housings, polished metal, and cover lenses have to survive the build and the trip without a scratch, a fingerprint, or a residue mark, and that is a temporary-film job.
Two constructions cover it. Adhesive low-tack polyethylene film (acrylic pressure-sensitive adhesive) gives a controlled, residue-free peel on painted and glossy surfaces — the controlling property is peel adhesion (ASTM D3330), matched low enough to lift cleanly but high enough to stay put, plus a UV/exposure window (typically stated in weeks-to-months) beyond which the adhesive can transfer.
Self-wound PVC cling film protects without any adhesive where even a low-tack residue risk is unacceptable. And where the covered face is itself ESD-sensitive, the film must be qualified for low charging, not only for tack, so it does not tribocharge on peel. Name the finish and the exposure time on the drawing; the film tack and UV window follow from them.
Protective liners during assembly: shielding fixtures & work surfaces
Damage does not only happen in the box; it happens on the bench. During assembly, a finished face resting on a bare fixture, a board sliding across a jig, or a housing set down on a work surface picks up scratches and marks that packaging cannot undo. Die-cut protective liners fix that: UHMW-PE liner for the low-friction, abrasion-resistant slip surface a part slides across; pressed felt for the soft, conformable pad a polished or painted face rests on; and thin PE foam for the cushioned nest a part sits in between operations.
These are to the fixture and the work-surface outline, often with a PSA back so they stay located. Send the fixture and nest geometry; the liner material follows from whether the duty is slip, cushion, or wipe. [6]
Moisture-barrier & static-shielding context: the bag around the kit
Around the foam and film sits the moisture-barrier or static-shielding bag, and the honest framing matters here: the bag's shielding and moisture performance are properties of the qualified bag system, not of a foam. A static-shielding bag is a metallized laminate whose discharge-shielding is evaluated by energy penetration per ANSI/ESD STM11.31-2018; a moisture-barrier bag (for moisture-sensitive devices) is a foil laminate whose water-vapor transmission is controlled per its spec (MIL-PRF-81705F Type I opaque foil or Type III transparent; WVTR per ASTM F1249).
H-O converts the films, papers, and laminates that make up barrier and interleaving layers, and the foam and desiccant nests that go inside, cited by designation; the bag-system qualification belongs to the tested bag. Note the shielding and moisture requirement on the drawing so the inserts are compatible with the bag system chosen. [5]
Reusable tote inserts & kitting: internal WIP flow and per-unit kits
Two related jobs close the page. First, reusable tote inserts: die-cut foam inserts fitted to a returnable tote or magazine that carry parts through internal work-in-process flow, indexed pockets protecting each part trip after trip. These are a durability decision — cross-linked PE foam, with its finer cells and better aging, outlasts single-trip EPE — and a resistance-class decision, since the tote insert is in contact with the parts as much as any packaging.
Second, kitting: H-O can combine the cavity insert, interleaving, protection film, and liners into a per-unit kit, parts on liner in assembly order, so the line pulls one kit per unit with lot-code TDS records for each material — the documentation an ESD-control program and a receiving inspection both want to see. Send the tote or magazine and the per-unit part list; the insert and the kit fall out of them.
Six decisions that drive your ESD-packaging spec
An ESD-safe protection kit is a set of single-purpose parts, and each has one controlling property. Miss one and the failure is rarely immediate: a foam picked by color instead of resistance class, a protection film that tribocharged on peel, a cushion that bottomed out, or an insulative layer that quietly became a charge source.
Materials carry resistance classes; programs and bag systems carry conformance. A surface-resistance class (conductive / dissipative / insulative per ANSI/ESD S541-2019) belongs to a material grade per its TDS, measured per STM11.11. ESD-control-program conformance (ANSI/ESD S20.20-2021), bag discharge-shielding (STM11.31-2018), and barrier-bag moisture performance (MIL-PRF-81705F) belong to the qualified system.
Write the resistance class on the part callouts, cite the program and bag standards by designation, and never let a drawing imply a foam is "S20.20 certified": the foam supports a program evaluated to it.
S541-2019 sets three surface-resistance classes: conductive ( < 1.0 x 104 Ω ), static dissipative ( 1.0 x 104 to < 1.0 x 1011 Ω ), and insulative ( ≥ 1.0 x 1011 Ω ). Dissipative materials are measured per STM11.11-2022; insulative per ASTM D257. S541-2019 reports resistance in ohms, not ohms/square. The foam and film on this page are the converter-side ingredients of an S20.20 packaging program.
Read the six factors below in order. The first two set the resistance class and the cushion; the next two carry the surface protection and the system context; the last two handle reuse and the low-charging edge case. Every factor names its test method, because in this application the documentation is part of the part.
Show all 6 selection factors tap to expand
Set the resistance class first, and specify it by number, not color
Rule — Fix the ANSI/ESD S541 class before the material, and write the surface-resistance target in ohms, not "black foam" or "pink foam." Conductive ( < 1.0 x 104 Ω ) gives the fastest controlled charge bleed; static dissipative ( 1.0 x 104 to < 1.0 x 1011 Ω ) gives a slower, controlled decay; insulative ( ≥ 1.0 x 1011 Ω ) is a charge risk near ESDS parts unless separately qualified for low charging.
The class is measured per STM11.11-2022 (dissipative) or ASTM D257 (insulative). Put the class and the measured resistance on the drawing; the family and grade follow from it. [2]
Size the cushion to the handling case, not the footprint
Rule — A cavity to the part outline locates the part; a cavity sized to the drop and handling case protects it. Set the foam density and cavity depth from the mass, the fragility, and the worst-case drop, so the cushion deflects without bottoming out on the container. Cross-linked polyethylene (XLPE) foam, with finer, more uniform closed cells and better aging, is the durable choice for reusable inserts; expanded polyethylene (EPE) is the economical single-trip choice.
Send the part mass, its fragility, and the handling/drop case; the foam grade and cavity geometry fall out of them. [3]
Match surface-protection film tack and exposure to the finish
Rule — A protection film is specified by peel adhesion and its exposure window, not just "tape." Match the peel (ASTM D3330) low enough to lift residue-free from a painted, anodized, or glossy face, but high enough to stay put during handling; then respect the film's UV/exposure window, beyond which a low-tack adhesive can transfer or a finish can mar on removal. Use self-wound PVC cling where any adhesive-residue risk is unacceptable. Name the finish and the exposure time on the drawing; the film construction, tack, and window follow. [6]
Keep system standards where they belong: at the packaging system
Rule — The foam and film carry material classes; the bag and the program carry system conformance. Bag discharge-shielding is evaluated by energy penetration per ANSI/ESD STM11.31-2018; moisture-barrier bags for moisture-sensitive devices are controlled per MIL-PRF-81705F (Type I opaque foil or Type III transparent; WVTR per ASTM F1249); and the whole handling scheme conforms to ANSI/ESD S20.20-2021.
Cite these by designation and let the tested bag or the audited program hold them. Note the shielding and moisture requirement on the drawing so the converted inserts are compatible with the bag system. [5]
Decide reuse early: single-trip EPE or multi-trip XLPE
Rule — Whether the part is single-trip transit packaging or a returnable internal tote insert changes the material. Single-trip interleaving and dunnage can be economical EPE; a tote or magazine insert that indexes parts trip after trip should be cross-linked PE foam, whose finer cells and aging resistance survive repeated handling without shedding or set.
The resistance class still applies either way, because a reusable insert is in constant contact with the parts. State the number of trips and the tote or magazine; durability grade follows from reuse, class from the parts. [2]
Watch the low-charging edge case: the film itself can zap the part
Rule — A protection film that is mechanically ideal can still be a charge source. Peeling an untreated insulative film off a display or a board tribocharges the surface, and the discharge can damage the very ESDS part it protected.
Where the covered face is ESD-sensitive, the film must be qualified for low charging (an antistatic or dissipative construction), not only for tack; the same logic applies to any insulative interleaving near sensitive parts. Flag every ESD-sensitive covered surface on the drawing so the film and interleaving are chosen for charge behavior, not only for protection. [1]
Specification Tools
Two tools to take you from "we're building a sealed enclosure" to here's the sealing kit for the drawing set: a requirement-driven IP sealing stack builder that assembles the part checklist with its material families and what-to-send notes, and a side-by-side comparison of every sealing family on this page.
1. ESD packaging stack builder
Check the protection requirements your parts carry. The builder assembles the corresponding parts into a checklist with the family, what to send with the drawing, and the correct standards language (resistance classes per ANSI/ESD S541 measured per STM11.11; program and bag-system standards by designation). The default selection below is pre-built for a typical board-and-module transit kit; every part is also printed in the material reference section, so nothing here exists only behind a script.
Protection kit checklist: 3 parts selected
Each checked requirement adds its part below. The list is the starting bill of materials for the engineering review, not a certification: resistance classes (per ANSI/ESD S541, measured per STM11.11) come from the grade TDS, and program/bag-system standards (ANSI/ESD S20.20, STM11.31, MIL-PRF-81705) are cited by designation, at the system level, not by any one foam or film.
2. Side-by-side: packaging & protection family comparison matrix
Every packaging and protection family called out on this page, with construction, the property that drives its selection, the standards its TDS cites, and the form it serves. Click a column header to sort. Click any material name to jump to its accordion entry.
| Material | Construction | Selection property | Standards on the TDS / by designation | Form | |
|---|---|---|---|---|---|
| ESD cushioning & interleaving (resistance class first) | |||||
| Cross-Linked Polyethylene (XLPE) FoamClosed-cell PE | Die-cut / routed foam | Resistance class + durability | S541-2019; STM11.11-2022 | Cavity inserts / trays | |
| Expanded Polyethylene (EPE) FoamExpanded PE | Die-cut sheet / pad | Dissipative class, economical | S541-2019 (per TDS) | Interleaving / dunnage | |
| ClipFoam (by Density)Clip / retention foam | Die-cut clip insert | Grip + density | S541 class (per TDS) | Retention inserts | |
| Foam Materials (broader family)Cushion foams | Die-cut cushion | Cushion / spacing | Per grade TDS | Cushion / blocking | |
| Surface protection, liners & grounding | |||||
| PolyMask PE Surface-Protection FilmLow-tack PE film | Adhesive PE film | Peel adhesion + exposure | ASTM D3330 (per TDS) | Display / housing | |
| Protective Films (general)Protective film | Slit / film | Tack level + backing | ASTM D3330 (per TDS) | Build + transit | |
| Self-Wound PVC Cling FilmAdhesive-free cling | Cling PVC film | Cling, no residue | Per grade TDS | Residue-free faces | |
| UHMW-PE Engineering Film & LinerUHMW-PE | Die-cut liner / strip | Low friction + abrasion | Per grade TDS | Fixture / slip liner | |
| SAE Pressed FeltPressed felt | Die-cut felt pad | Soft, conformable wipe | SAE grade (per TDS) | Interleaving / wipe | |
| BISCO® Conductive SpongeConductive silicone | Die-cut sponge | Volume / surface resistance | ASTM D991 / D257 (per TDS) | Grounding contact | |
Skip ahead and request your engineering review now
If your drawing set already calls out a resistance class, a PE-foam cavity insert, an interleaving or dunnage set, a surface-protection film, or a tote insert, send it over for engineering review against the TDSs and the standards language.
ESD-packaging failures you can prevent at spec
ESD-safe packaging fails quietly first: a foam picked by color instead of resistance class, a protection film that tribocharged on peel, a cushion that bottomed out, a system standard claimed for a part, or a single-trip foam pressed into reusable service. Five patterns cover most of what goes wrong, and each is a specification decision made before the first part is cut.
Resistance class is a material property; program and bag conformance are system properties. A foam picked by color, or a drawing that claims "STM11.31" or "S20.20 certified" for a part, costs more schedule at the ESD audit than any cutting error. Cite resistance classes per S541 (measured per STM11.11) on the TDS, and cite program and bag-system standards by designation.
Show all 5 failure modes tap to expand
1. Foam specified by color, and the resistance class was wrong
Fix — specify the ANSI/ESD S541 surface-resistance class in ohms, not "black" or "pink." A drawing that says "black conductive foam" assumes a color maps to a class, but vendor color conventions overlap and antistatic values shift with humidity, so the part can land in the wrong resistance decade against a sensitive device. The failure is silent: the packaging looks correct and the ESD event happens anyway.
Write the class (conductive < 104 Ω, or dissipative 104–< 1011 Ω) and the measured surface resistance per STM11.11 on the drawing, and let the grade and TDS confirm it at 12% and 50% RH. [2]
2. The protection film tribocharged the part on peel
Fix — qualify any film over an ESD-sensitive face for low charging, not only for tack. A low-tack film is chosen purely for clean removal from a display, it protects the surface perfectly through the build, and then peeling it off an untreated insulative backing tribocharges the face and discharges into the device it was protecting. The film was a good protective film and a poor ESD film.
Where the covered surface is ESD-sensitive, specify an antistatic or dissipative film construction qualified for low charging, and apply the same logic to any insulative interleaving sitting against sensitive parts. [1]
3. The cavity fit the outline but bottomed out on the drop
Fix — size foam density and cavity depth to the drop/handling case, not just the footprint. A cavity to the part outline locates the part beautifully and still transmits a damaging shock, because the floor was too thin or the density too high to deflect on the worst-case drop. Cushioning is a mechanical decision separate from the fit: the foam has to deflect and absorb without bottoming out on the container wall.
Send the part mass, its fragility, and the handling/drop case, choose the foam density and cavity depth from those, and reserve the tightest-fitting outline for location, not for protection. [3]
4. A part that claimed a system-level listing
Fix — cite program and bag-system standards by designation; never claim them for a foam or film. A drawing note reads "MIL-PRF-81705 moisture-barrier foam" or "STM11.31 shielding insert," and the ESD or receiving audit stalls, because those standards belong to the tested bag system and the audited program, not to a converted part. The material carries its own class (S541, measured per STM11.11); the bag carries its shielding and moisture performance.
Write material classes on the part callouts, cite ANSI/ESD S20.20, STM11.31, and MIL-PRF-81705 by designation at the system level, and make the converted inserts compatible with the qualified bag. [5]
5. A single-trip foam pressed into reusable service
Fix — use durable cross-linked PE foam for reusable tote inserts; reserve EPE for single-trip. An economical expanded-polyethylene insert is specified for a returnable tote to save cost, and within a few cycles it sheds, takes a set, and loses the cavity that indexed the part, so protection and location both degrade trip after trip. The material was right for single-trip transit and wrong for multi-trip WIP flow.
Decide the number of trips up front: cross-linked PE foam, with its finer cells and aging resistance, for reusable tote and magazine inserts; EPE for single-trip interleaving and dunnage, keeping the resistance class on both because either is in contact with the parts. [2]
Material reference
Detailed specs for the eight packaging and protection families referenced on this page: the ESD cushioning (cross-linked PE foam, expanded polyethylene, ClipFoam), the surface protection (PolyMask / protective PE film, self-wound PVC cling), the assembly liners (UHMW-PE liner, pressed felt), and the grounding contact (BISCO® conductive sponge).
Values are per the maker TDS on file for each grade with the method named; surface-resistance classes are per ANSI/ESD S541-2019 measured per STM11.11-2022, and program and bag-system standards are cited by designation only, held by the qualified system.
H-O die-cuts, kiss-cuts, laminates, and slits every family to drawing.
Cross-Linked Polyethylene (XLPE) FoamESD cavity inserts & trays · ANSI/ESD S541 class, STM11.11 method · fine closed cells, durable
Specify the S541 class and the measured surface resistance, not the color, and size density and cavity depth to the drop case. The sibling display / PCB & shock-protection page carries the deep in-device cushioning playbook.
Expanded Polyethylene (EPE) FoamInterleaving, dunnage & single-trip cushioning · dissipative grades per S541 · economical
Keep the S541 class on interleaving and dunnage, because either sits against the parts; for reusable service step to cross-linked PE foam.
ClipFoam (by Density)Die-cut clip & retention inserts · grip + density · dissipative grades available
Send the part outline and mass; density and slot geometry follow. For ESD-sensitive parts, hold the S541 class on the clip foam as on the cavity.
PolyMask & Protective PE Surface-Protection FilmDisplays & painted / anodized housings · peel adhesion per ASTM D3330 · residue-free removal
Match the film to the finish. Name the surface and the exposure time on the drawing; the tack level, backing, and UV window follow, and are validated on the real finish before a full run.
Self-Wound PVC Cling FilmAdhesive-free surface protection · cling, no residue · residue-sensitive finishes
Use where residue is unacceptable; where the film must stay firmly located under handling, the adhesive low-tack PE film is the better match. State the finish so cling vs. adhesive is chosen correctly.
UHMW-PE Engineering Film & LinerFixture & work-surface protection · low friction, abrasion resistant · slip liner
Send the fixture and nest geometry; the liner grade follows from whether the duty is slip, wear, or support. UHMW-PE is the slip surface; pressed felt is the soft rest surface.
SAE Pressed FeltSoft interleaving, wiping & interface liners · SAE grade per TDS · conformable
Felt is the soft, non-marring counterpart to the UHMW-PE slip liner; pick by whether the duty is slide (UHMW) or rest/wipe (felt).
BISCO® Conductive SpongeGrounding-contact & bonding duty · ASTM D991 / D257 · conductive silicone
This is a conductive contact material, distinct from the cushioning foams; the sibling EMI shielding & grounding page carries the deep grounding-contact playbook.
Skived PTFE Film (DeWAL® DW2000, 6113-05, 6113-10)
Lowest friction on the page · 0.0005″–0.040″ (DW2000 TDS) · AMS 3662 cited
ESD packaging & surface protection: engineer-grade FAQ
Twelve of the questions we hear most from packaging, ESD-control, and manufacturing teams. If your question isn't here, send a drawing or call, engineering picks up.
Is an ESD foam "S20.20 certified" or "STM11.31 rated" on its own?
No, and no honest supplier will say otherwise. ANSI/ESD S20.20 is an ESD-control program standard a facility conforms to; ANSI/ESD STM11.31 is a bag discharge-shielding test method; MIL-PRF-81705 is a barrier-material spec — all belong to the tested bag system or the audited program, not to a foam or film. What a converted part carries is its own material class: a surface-resistance class per ANSI/ESD S541 measured per STM11.11, and any UL 94 flame class, per its TDS.
Write the material class on the part callout and cite the program and bag standards by designation. [1]
What is the difference between conductive, dissipative, and insulative packaging?
They are three surface-resistance classes under ANSI/ESD S541-2019. Conductive is < 1.0 x 104 Ω (with a field-shielding sub-class < 1.0 x 103 Ω) and gives the fastest controlled charge bleed; static dissipative is 1.0 x 104 to < 1.0 x 1011 Ω and gives a slower, controlled decay; insulative is ≥ 1.0 x 1011 Ω and is a charge risk near sensitive parts unless separately qualified for low charging.
Dissipative materials are measured per STM11.11-2022; insulative per ASTM D257. Specify by class in ohms, not by color. [2]
Is "black foam is conductive, pink foam is antistatic" a reliable spec?
Color is a hint, not a spec. As a rough convention conductive PE foam is often black (typically ~103–105 Ω surface resistance) and antistatic/dissipative PE foam is often pink (vendor ranges commonly ~106–1011 Ω), but vendor color conventions overlap and antistatic values shift with humidity. The reliable spec is the ANSI/ESD S541 class and the STM11.11-measured surface resistance on the grade TDS, characterized at 12% and 50% RH. Put the class and the measured resistance on the drawing and let the TDS confirm it. [3]
Cross-linked PE foam or expanded polyethylene for a cavity insert?
By reuse and durability. Cross-linked polyethylene (XLPE) foam has finer, more uniform closed cells and better aging resistance, so it survives repeated handling — the right choice for reusable cavity and tote inserts. Expanded polyethylene (EPE) is the economical single-trip choice for interleaving, dunnage, and one-way transit cushions.
Both are available in dissipative and conductive grades, so the S541 class is a separate decision from the XLPE-vs-EPE durability decision. State the number of trips and the resistance class, and the foam grade follows. [3]
How do I size a foam cavity so it actually protects the part?
Size it to the drop and handling case, not just the part outline. A cavity cut to the outline locates the part but can still transmit a damaging shock if the floor is too thin or the density too high to deflect on the worst-case drop. Set the foam density and cavity depth from the part mass, its fragility, and the drop height so the cushion deflects without bottoming out on the container, and reserve the tightest-fitting outline for location.
Send the part mass, fragility, and handling/drop case; density and cavity geometry fall out of them. [3]
How do I pick a surface-protection film for a display or painted housing?
By peel adhesion and exposure window, matched to the finish. Use a low-tack polyethylene film (acrylic PSA) with a peel per ASTM D3330 low enough to lift residue-free from a painted, anodized, or glossy face but high enough to stay put during handling, and respect the film's UV/exposure window (typically stated in weeks to months on the TDS) beyond which the adhesive can transfer or a finish can mar. Where any adhesive residue is unacceptable, use a self-wound PVC cling film instead. Name the finish and the exposure time; the film follows. [6]
Can a protection film itself damage the part when I peel it off?
Yes — it is a real and often-missed failure. Peeling an untreated insulative film off a display or a board tribocharges the surface, and that discharge can damage the very ESD-sensitive part the film protected. A film that is mechanically ideal can still be a poor ESD film. Where the covered face is ESD-sensitive, specify an antistatic or dissipative film construction qualified for low charging, not only for tack, and apply the same caution to any insulative interleaving sitting against sensitive parts. Flag the ESD-sensitive faces on the drawing. [1]
What is a static-shielding bag versus an antistatic bag, and where does the foam fit?
A static-shielding bag is a metallized laminate whose discharge-shielding is evaluated by energy penetration per ANSI/ESD STM11.31-2018; an "antistatic" bag is typically a dissipative film that resists charge generation but does not shield. The PE foam H-O converts rides inside the bag as the cushion and cavity, classified by its own S541 surface-resistance class; the bag's shielding belongs to the tested bag system.
Note the shielding requirement on the drawing so the converted inserts are compatible with the bag chosen, and cite the bag standard by designation. [5]
What is MIL-PRF-81705, and which type is a moisture-barrier bag?
MIL-PRF-81705 (current revision F, 2023) is the specification for flexible, heat-sealable, electrostatic-protective barrier materials. It defines Type I (opaque, water-vapor-proof, electrostatic + electromagnetic shielding — the foil-laminated moisture-barrier type) and Type III (transparent, waterproof, static-shielding). It defines no Type II or Type IV.
Water-vapor transmission of the barrier material is characterized per ASTM F1249 (with MIL-STD-3010 methods). It is a barrier-material spec, cited by designation; the foam inside the bag carries only its own S541 class. [5]
At what humidity are ESD surface-resistance numbers measured, and why does it matter?
At a worst-case dry condition and at ambient — commonly 12 ± 3% RH and 50 ± 5% RH. Humidity matters because many antistatic treatments on PE films and foams are hygroscopic: they perform well at 50% RH and can drift toward insulative as the air dries out, so a material qualified only at ambient can fall out of its dissipative class in a dry warehouse or a winter shipment.
Ask for the surface-resistance class at the dry condition on the TDS, not just at ambient, and hold the S541 class across the humidity range the parts will see. [3]
Does H-O make the ESD bags themselves, or the parts inside them?
H-O and converts the parts: the conductive and dissipative PE-foam cavity inserts, trays, interleaving, and dunnage; the low-tack surface-protection film and PVC cling; the UHMW-PE and felt liners; and the film, paper, and laminate layers that make up barrier and interleaving. Where a job needs a qualified static-shielding or moisture-barrier bag system, that is a bag-maker's tested product, cited by designation; H-O supplies the converted parts that ride with it and the inserts inside it, with material classes per TDS and lot-code traceability. [1]
What should I send so the ESD-packaging quote comes back right the first time?
The part footprint or drawing; the surface-resistance CLASS target (conductive or dissipative); the drop/handling case and part mass (for cushion depth and density); the finish being protected and its exposure time (for film tack and UV window); whether the part is single-trip or a reusable tote insert; any moisture-barrier or shielding requirement (bag-system, by designation); adhesive or liner needs; and prototype plus annual volumes.
"Recommend the protection kit" is a valid callout: that is what the engineering review is for. H-O can kit the whole set, one kit per unit, with lot-code TDS records per material.
Glossary: terms used on this page
Quick reference for the ESD-packaging, surface-resistance, and material terminology used throughout. Each entry links to the relevant standard or test method where applicable.
ANSI/ESD S541 (packaging classes)
The packaging-materials standard, per ANSI/ESD S541-2019 [2], that defines the conductive, static-dissipative, and insulative surface-resistance classes used to specify ESD packaging. It reports resistance in ohms; the class is a material property.
Conductive / dissipative / insulative
Conductive = < 1.0 x 104 Ω surface resistance (field-shielding sub-class < 103 Ω); static dissipative = 1.0 x 104 to < 1.0 x 1011 Ω; insulative = ≥ 1.0 x 1011 Ω, per S541.
ANSI/ESD STM11.11 (surface resistance)
The surface-resistance test for static-dissipative planar materials, per ANSI/ESD STM11.11-2022 [3]; it measures 1.0 x 104 to < 1.0 x 1011 Ω and replaces ASTM D257 for dissipative materials.
Ohms vs ohms/square
Ohms/square (Ω/□) is surface resistivity, a size-independent material property; ohms (Ω) is surface resistance, dependent on electrode geometry and specimen size. S541-2019 deliberately reports resistance in ohms.
ANSI/ESD S20.20 (program standard)
The ESD-control program/management standard, per ANSI/ESD S20.20-2021 [1], for handling items sensitive to ≥ 100 V HBM / ≥ 200 V CDM. A facility conforms to it; a foam does not.
ANSI/ESD STM11.31 (bag shielding)
The bag discharge-shielding test that measures energy penetration (in nanojoules) through a shielding bag, per ANSI/ESD STM11.31-2018 [4]. A property of the tested bag, not of an insert.
MIL-PRF-81705 (barrier bags)
The flexible barrier-material spec, per MIL-PRF-81705F [5]: Type I (opaque foil, moisture + EMI + static shield) and Type III (transparent, static shield). A bag-material spec; water-vapor transmission per ASTM F1249.
HBM / CDM
Human Body Model (HBM) and Charged Device Model (CDM): the two ESD event models that set a device's sensitivity threshold and, with it, whether an ESD-control program (S20.20) and packaging classes are required.
MSD (moisture-sensitive device)
A component that can be damaged by absorbed moisture during reflow; it ships in a moisture-barrier bag with desiccant and a humidity indicator. The bag's water-vapor transmission is characterized per ASTM F1249 [7].
XLPE vs EPE
Cross-linked polyethylene (XLPE/IXPE) foam has finer, more uniform closed cells and better aging — the durable choice for reusable inserts. Expanded polyethylene (EPE) is the economical, coarser single-trip foam for interleaving and dunnage.
Low charging (tribocharging)
Tribocharging is the charge generated when two surfaces separate, such as peeling a film. A packaging material qualified for low charging generates little charge on separation; this is a separate qualification from tack, and per ASTM D3330 [6] peel is only the adhesion half of the decision.
Conformance belongs to the qualified system
The honesty rule for ESD claims: program conformance (S20.20), bag shielding (STM11.31), and barrier moisture performance (MIL-PRF-81705) attach to the audited program or the tested bag system, not to a foam or film. The converted part carries only its own S541 class.
Last updated · Reviewed by H-O Products engineering (ISO 9001:2015 certified converter, Winsted, CT).
Standards, test methods & technical references
The standards, test methods, and technical references cited throughout this page. Program and bag-system standards (ANSI/ESD S20.20, STM11.31, MIL-PRF-81705) are cited by designation: they belong to the audited program or the tested bag system, not to a foam or film. Standards editions current as of July 2026; verify against the publishing body before final spec. H-O materials are aligned to these standards through the source manufacturer's TDS, not independently certified by H-O unless explicitly stated on the quote.
[1] ANSI/ESD S20.20-2021
Protection of Electrical and Electronic Parts, Assemblies and Equipment (Except Electrically Initiated Explosive Devices) — the ESD-control program/management standard for handling items sensitive to ≥ 100 V HBM / ≥ 200 V CDM. Cited by designation; a facility conforms, a converted part does not. EOS/ESD Association, Inc. webstore.ansi.org (ANSI/ESD S20.20-2021)
[2] ANSI/ESD S541-2019
Packaging Materials for ESD Sensitive Items — defines the conductive ( < 1.0 x 104 Ω ), static-dissipative ( 1.0 x 104 to < 1.0 x 1011 Ω ), and insulative ( ≥ 1.0 x 1011 Ω ) surface-resistance classes used throughout this page; reports resistance in ohms. EOS/ESD Association, Inc. webstore.ansi.org (ANSI/ESD S541-2019)
[3] ANSI/ESD STM11.11-2022
Surface Resistance Measurement of Planar Materials — the DC test method for the surface resistance of static-dissipative planar materials ( 1.0 x 104 to < 1.0 x 1011 Ω ), recommended by the ESDA in place of ASTM D257 for dissipative materials. EOS/ESD Association, Inc. webstore.ansi.org (ANSI/ESD STM11.11-2022)
[4] ANSI/ESD STM11.31-2018
Evaluating the Performance of Electrostatic Discharge Shielding Materials — Bags — the energy-penetration test that characterizes the discharge-shielding of a shielding bag. A property of the tested bag system, cited by designation. EOS/ESD Association, Inc. webstore.ansi.org (ANSI/ESD STM11.31-2018)
[5] MIL-PRF-81705F
Barrier Materials, Flexible, Electrostatic Protective, Heat-Sealable (Revision F, 2023). Defines Type I (opaque, water-vapor-proof, electrostatic + electromagnetic shielding, foil laminate) and Type III (transparent, waterproof, static-shielding); water-vapor transmission per ASTM F1249. A barrier-material spec, cited by designation. DLA/ASSIST. quicksearch.dla.mil (MIL-PRF-81705)
[6] ASTM D3330
Standard Test Method for Peel Adhesion of Pressure-Sensitive Tape. The method behind the peel-adhesion data used to match a low-tack surface-protection film to a painted, anodized, or glossy finish, reported at the stated substrate. ASTM International. astm.org (ASTM D3330)
[7] ASTM F1249
Standard Test Method for Water Vapor Transmission Rate Through Plastic Film and Sheeting Using a Modulated Infrared Sensor. The water-vapor-transmission method referenced by MIL-PRF-81705 for moisture-barrier bag material. ASTM International. astm.org (ASTM F1249)
[8] ASTM D257
Standard Test Methods for DC Resistance or Conductance of Insulating Materials. The resistance method for insulative materials; for static-dissipative planar materials the ESDA recommends STM11.11 instead. ASTM International. astm.org (ASTM D257)
[9] UL 94
Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances. The flame-class basis (HB, V-0) listed by grade and thickness on the material TDS where a packaging or protection grade carries one; cited by designation, listed for the material grade. UL Standards & Engagement. shopulstandards.com (UL 94)
[10] IEC 61340-5-1
Protection of electronic devices from electrostatic phenomena — General requirements. The international counterpart to the ANSI/ESD program framework, including packaging requirements referencing shielding energy-penetration limits; cited by designation as context. IEC. webstore.iec.ch (IEC 61340-5-1)
Updated . Standards editions and links current at publication; verify against the publishing body before final spec. H-O materials are “aligned to” the standards cited; lot-specific qualification documentation available on request.
To review your ESD-packaging & surface-protection design, send:
- Part footprint / drawing
- Surface-resistance class target (conductive / dissipative)
- Part mass & drop / handling case
- Finish being protected & its exposure time
- Single-trip or reusable tote insert
- Moisture-barrier / shielding need (by designation)
- ESD-sensitive faces (for low-charging film)
- Adhesive / liner requirements
- Interleaving, dunnage & kitting needs
- Prototype & annual volume
Get an ESD-packaging engineering quote
Send a drawing set, BOM, or part spec. We typically respond within one business day with a protection-kit recommendation, prototype lead time, and TDS verification against your surface-resistance class, cushioning duty, film tack, and standards language.
See also: related H-O application pages
Engineering content for the adjacent electronics and IoT sub-applications and the parent hub. Each page covers material selection, failure modes, and converter-side process detail for its application family.
Sibling sub-application
Outdoor, IP-rated & harsh-environment sealing
The sealing companion for the shipped product itself: closed-cell perimeter gaskets and the weather, chemical, and wash-down duty of the enclosure this packaging protects.
Read the page
Sibling sub-application
Display, PCB & shock protection
The in-device cushioning and drop/shock playbook this page's transit inserts complement: the foams that protect the screen and boards inside the product.
Read the page
Sibling sub-application
EMI shielding & grounding
The grounding-contact companion: conductive gaskets and the conductive sponge that ties parts, trays, and fixtures to ground in an ESD-safe scheme.
Read the page
Sibling sub-application
Electronics thermal management
The thermal side of the same product: die-cut thermal interface pads, gap fillers, and heat-spreading materials inside the housing.
Read the page
Industry hub
Electronics & IoT
The full electronics and IoT application family: sealing, EMI, thermal, display and shock protection, insulation, and ESD packaging.
Read the page
Sibling sub-application
Electrical insulation & dielectric
The dielectric-film companion: die-cut Kapton® and PET insulating barriers and the film, paper, and laminate families that also appear in this page's barrier context.
Read the page
Material data & standards. All surface-resistance, peel-adhesion, and moisture-transmission values on this page are taken from the source maker's technical data sheets with the method named (ANSI/ESD S541-2019 classes measured per STM11.11-2022; ASTM D257, D3330, F1249; UL 94 classes per the listed grade TDSs).
Program and bag-system standards (ANSI/ESD S20.20-2021, STM11.31-2018, MIL-PRF-81705F, IEC 61340-5-1) are cited by designation only: they belong to the audited ESD-control program or the tested bag system, and the materials on this page support designs and programs evaluated to them.
Vendor foam and film resistance values quoted as "typically" are approximate and grade-dependent; the S541 class and the grade TDS govern. H-O converts materials; H-O does not certify ESD-control programs or bag systems, and does not independently certify materials against the standards unless explicitly stated on the quote. Verify against the maker TDS and your system-level qualification plan.
Conversion scope. H-O and converts sheet, roll, and foam stock to drawing in Winsted, Connecticut: die-cut and kiss-cut foam inserts, trays, and interleaving, slit films and liners, laminations, and kitted per-unit protection sets, with material traceability and lot-code TDS records. H-O and converts rather than molding or extruding; molded parts and extruded profiles are coordinated through a partner network. Lead-time and MOQ details are in the process strip and the quote form above.