Foam Engineering & Packaging Solutions


The foam puzzle was designed by MSA apprentice Katie Flaherty, her first CAD job, as part of her learning practice. Katie used Solid Works™ to design the foam, visualising it in 3D to perfect the puzzle and ensure a precision fit in the Peli 1510 case. Finger pockets were added at each side to easily remove the puzzle from the case.


LD45 black on yellow foam, comprising of 120mm thick yellow foam with a 5mm layer of black foam, was chosen to manufacture the puzzle. Production drawings were created with Alphacam™ software and the foam was routed with a CNC machine as a whole before being cut into the puzzle segments. As a finishing touch, the edges of the puzzle have been stepped to reveal the yellow foam.

Can you solve it? Test your spatial intelligence with the foam puzzle at Southern Manufacturing, Farnborough from the 21st to 23rd March 2017 on the MSA stand, N8.

Visit: for full details about the show.

Submitting CAD Files

Submitting your designs couldn’t be easier

Fill in the form below and attach the CAD file and send it to us, once recieved, we will review the design and information requested and contact you regarding your order as soon as possible.

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Our Nationwide Representatives

We are the only custom foam company in the UK with a nationwide team.

This means that we can come to you and begin the consultation process quicker than anyone else can.

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