Polyethylene Foam: An Excellent Material for Automotive Dunnage Racks


Dunnage racks are used to store and transport parts within an automotive factory. Dunnage racking also ensures the safe delivery of each part in a manufacturing environment.

Benefits include:

  • Effectively protects parts from scratches and dents.  
  • The custom ergonomic design allows for easy lifting.
  • Reusable and reduces long-term costs, plus reduces the amount of waste sent to landfills.
  • Easier storage due to stackable design We work with our customers to design each packaging solution to fit the needs of each project, with customizable options.

Our goal is to always design the package system projects to protect the finish on each item, utilizing fabricated foam assemblies. We select and use the most durable foam materials to create the best packaging solutions for transport to anywhere. 

Recently, Merryweather Foam was approached by an OEM automotive company to manufacture a series of custom designed foam to fit dunnage rack systems. The foam we recommended is a type of polyethylene foam. We chose this particular foam because it is both cost effective and durable. 

First, we started the fabrication process by water jet cutting the polyethylene material to match the custom design of the pieces to fit the rack. Next, we added grooves to each of the foam pieces by routing the material. Finally, we packaged and shipped the dunnage rack shelves to our customer. 

Throughout the entire foam fabrication process, we were able to hold tightest tolerances of ± .040”. Our goal is to always provide solutions that help you achieve cost-savings on each shipment, along with providing a solution that helps eliminate waste. For more information about how our capabilities can help with your next project, please contact us and we will be happy to assist you.

Since 1948, we have been industry leaders in fabricating unique foam components for customers in the medical, sound absorption, automotive, and packaging industries. At Merryweather Foam, we pride ourselves on our ability to combine experience, innovation, and excellent customer service. We have the knowledge, manpower and equipment to help you get the job done.

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