Industry solutions
Medical Device Packaging Foam
Tijuana is the largest medical-device manufacturing hub in North America — and IPS makes foam a short drive from the plants that need it. Device kits, surgical instruments, and diagnostic equipment ride in cavity inserts we engineer around the exact geometry of each component.
Fine-cell cross-linked polyethylene (XLPE) is the workhorse here: non-abrasive, low-particulate, and clean-cutting, so routed cavities present devices cleanly and hold them firmly through sterilization logistics and distribution. For heavier instruments and shippers, standard PE adds economical impact protection.
Because we engineer, prototype, and produce locally, packaging development keeps pace with device programs: a cavity revision is a drive across town, not a container on the ocean.
Foam applications
- Device kit trays with routed component cavities
- Instrument case inserts, single and multi-layer
- Shipper cushioning for pumps, monitors, and diagnostic units
- Convoluted PU lining for cases and totes
- Reusable totes with engineered dunnage for line-side handling
- Layer pads and separators for sterile-packaged goods cartons
Technical specifications
| Typical materials | XLPE for device contact and premium trays; PE for shippers; convoluted PU for case lining |
| Cutting | CNC wire cutting for cavity work — no tooling charge, fast revisions during device development |
| Surface | Fine-cell, non-abrasive XLPE for delicate housings and polished surfaces |
| ESD option | Anti-static PE for devices with sensitive electronics |
| Development | Physical samples before production; engineering support in English and Spanish |
| Logistics | Local delivery across Tijuana/Baja and cross-border shipping into the US |
Example applications
Device kit tray
Multi-cavity XLPE tray holding a handheld device, cables, and accessories in a branded kit box — every component visible and secured.
Instrument transit case
Two-layer PE insert set for a diagnostic instrument and its probes, designed to survive repeated courier shipment between facilities.
Line-side dunnage
Reusable PE dunnage trays that move subassemblies between maquiladora production cells without surface damage.
Frequently asked questions
Why is XLPE preferred for medical device trays?
Cross-linked polyethylene has a fine, closed-cell structure that cuts cleanly, sheds virtually no particles, and won't abrade delicate housings — so cavities look sharp and protect device surfaces through handling and transit.
Can you work directly with our Tijuana plant?
Yes — we're local. IPS is based in Tijuana and supplies maquiladoras across Baja California, with bilingual engineering support and local delivery, plus cross-border shipping to US distribution points.
How fast can we iterate a tray design?
CNC wire cutting works straight from CAD with no tooling, so cavity revisions can be recut and back in your hands in days — critical while a device program is still evolving.
Do you hold medical certifications?
IPS is a foam fabricator, not a sterile-packaging converter — we produce protective trays, inserts, and dunnage to your specification. For applications with specific regulatory requirements, we work to the specs your quality team defines.