Developed in collaboration with a customer, this EVA foam block was made to protect and transport an 8-inch drone. The foam design can be scaled up or down and tailored to any drone size and configuration. FFG integrated the customer’s 3D CAD models and 2D drawings, then completed design refinement and updates. The project progressed through prototype, pilot, production and delivery, with options for carrying-bag, rigid-case or standalone integration.
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The prototype underwent a static fit check. The pilot received approval following field testing, and the project subsequently reached production and delivery. The test methods, conditions and detailed results have not been disclosed.
The customer supplied the initial 3D and 2D CAD files. FFG managed their integration and refined and updated the foam design in collaboration with the customer. This example illustrates how FFG can develop a foam component from an existing customer definition.
The EVA foam layers are die-cut and glued together to form the block. Additional CNC machining completes the fine details. This manufacturing route combines layered foam construction with machined detail finishing.
The foam block can be integrated into a carrying bag or backpack, with textile development support from FFG Bags, or into a rigid protective transport case. For a similar application, define the drone configuration, internal container dimensions, closure clearance and access needed to insert and remove the equipment.
A standalone block can be developed for customer integration or used as a drone stand and work-in-progress (WIP) support during production or maintenance. The support points, access to the drone and handling requirements should be defined for the intended task.
EVA is an ethylene-vinyl acetate copolymer. Manufacturers offer lightweight, flexible and resilient closed-cell EVA foams for packaging and padding, with low water absorption in the grades described by the sources below. These are material-family characteristics, separate from this project’s specification. For a similar design, confirm the exact grade, hardness scale, compression response, recovery after sustained loading and temperature limits with the supplier, then validate the complete foam and container assembly for its intended use.
Share the part or assembly drawing, overall dimensions, material or grade if known, interfaces, quantities and timing. Include the requirements you need to validate.
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