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Cutting foam inserts for gift boxes

Cutting foam inserts for gift boxes

Tom and Karen Couper have just opened their beautiful new shop, The Wee Couper of Fife,  in Anstruther where they sell boxed miniature sets.

Bespoke inserts for a range of products

Tom and Karen wanted to make up their own unique gift sets. They sourced boxes with foam inserts, but these inserts just came as a whole square. The Coupers needed to have shapes cut out of the inserts to match the 14 individual gift sets they planned to start with. Holes were required for bottles, hipflasks, golf balls and jams. And they needed to be snug so that the products would fit in the boxes securely.

The Wee Couper of Fife's Grant's, Hendricks and Grey Goose gift set
The Wee Couper of Fife’s Grant’s, Hendricks and Grey Goose gift set

Can you laser cut foam?

Tom and Karen came to the workshop to show me what they wanted to see if I could help.

Tom had mocked up a gift box to show me how he wanted them to look by cutting one foam square with a knife. It looked smart! But the question was, could I laser cut the foam for them? I’d asked Tom to check if the foam contained any PVC or teflon as they evolve acid gases during cutting, but his supplier confirmed that they didn’t and that they were suitable for laser cutting.

I had only cut closed cell foam prior to this. It cut well and the facing side looked good. But on the back, in areas where the machine slowed down to change direction, the foam melted a bit, creating pits. I tested the sample that the Coupers had brought and found settings that worked. Again, the facing side looked great, but areas on the back where angles had been cut, there were small melted pits. Tom and Karen didn’t mind as they wouldn’t be seen.

Creating artwork for the 14 foam insert styles

Now we knew I could help, the next stage was to create artwork. Fourteen files were needed, one for each set. I’m not a graphic designer, but I work with a few, and one of them is CatMac Design. Catriona created the artwork in vector format, sent it to me to check, and we were ready to go.

Grand opening!

Two weeks ago, Tom brought round the first box of foam to the workshop to cut.

On Friday 15th June, Tom and Karen proudly opened their new shop. Here’s a picture of Tom looking splendid in his uniform kilt with one of the box sets. I love the little half keg display units on the wall behind him, each containing a different gift set.

Wee Couper opening

 

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