Reply by MadMark

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Posted on Custom Cases/Boxes: Foam

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979 posts in 2374 days

#1 posted 08-06-2016 03:47 AM

Assume the Styrofoam is 2’ thick. You draw the object outline & melt away the cavity with a soldering iron, test fitting as you go. The completed cavity is flocked, but the top of the styro is still flat. You put flat sticky felt on the Styrofoam surface and then cut out the shape of the flocked cavity. When the item is inserted into the flocked cavity for display, only the felt will show. With the item removed, the felt & flocking will match for a clean professional look.

For a medal box just leave the Styrofoam uncut and give a piece of green and blue felt. Medal pins will push thru & hold & the cust can use either felt (green/Army, blue/Navy).

I’ve sold them by the dozen at the local Army/Navy shop.


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