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From Prototype to Production: Your Partner in Medical Packaging Foam
When a medical device OEM set out to reshore insulin pump packaging production from China to the United States, the packaging had to protect against external impact, vibration, moisture, and contaminants — while keeping the device clean from factory to patient. Here is how we got there.
The challenge
The OEM needed U.S.-produced protective packaging for an ambulatory insulin pump. Beyond physical protection, the foam had to maintain device cleanliness and prevent contamination, and the only starting documentation was a set of Chinese technical specifications.
Material selection: the right foam, not the expensive one
Rather than defaulting to a costly static-proof foam, our engineers determined that a standard 1.7 lb. polyethylene foam was the more suitable and economical option for this application — it met the protection and cleanliness requirements without paying for properties the device didn't need.
Design and prototyping
Engineers interpreted the original technical specifications and developed custom foam inserts around the pump's geometry. Prototypes were produced and tested to validate fit and protective function before committing to production.
Custom tooling and quality control
Waterjet cutting held tolerances of ±0.1 inches for precise fit and optimal protection. Rigorous inspection processes backed the production run, with additional verification by the customer both on receipt and after assembly.
The result
The OEM reported the solution exceeded expectations in quality, reliability, and performance — and gained a domestic supply chain for a critical packaging component in the process.
Reshoring or re-speccing a packaging component?
Send the device geometry, the protection requirements, and whatever documentation exists. Engineering interprets the specs, prototypes the insert, and validates fit before production.
Samples typically ship in 3 to 5 business days for common die-cut configurations; standard production runs about two weeks; special orders are quoted to the job.
Family-owned in Winsted, Connecticut since 1971 · ISO 9001:2015 certified · OEMs worldwide send us a drawing — and get back their part.
Frequently asked questions
Can H-O work from overseas specifications?
Yes — this project started from Chinese technical specifications. Engineering interprets the original drawings, develops the insert design, and validates it with prototypes before production.
Does medical packaging foam need to be anti-static?
Not always. In this case a standard 1.7 lb. polyethylene foam met the protection and cleanliness requirements at lower cost. The device and environment determine whether static protection is needed.
Request a quote for medical packaging foam
Send H-O your material role and geometry—engineering reviews every RFQ, recommends a family per material, and converts samples on your geometry.