Custom Shapes

Custom Shapes & PackagingCustom EPS Shapes

Cutting Method for EPS

At ICA we utilize the latest CAD-CAM (Computer Aided Design-Computer Aided Manufacturing) technologies as well as other innovative fabrication techniques to manufacture highly intricate designs and shapes. Our computer-controlled hot wire cutting grid can produce one or multiple sets of identical parts from a large block of molded EPS. Let our in-house design team assist you in creating the perfect product for your needs!

Advantages of EPS

Expanded polystyrene (EPS) is the perfect material for packaging displays and insulating panels. Our ICA-LITE® EPS can be manufactured in various densities to meet your specifications. It offers a very cost efficient way to make components without the costliness and long lead times of die-cut or molded parts. Recyclable EPS, with its excellent cushioning, resilience and high insulation value, is the optimal material for insulated packages.

Cut Your Own EPS

Hot KnifeThe Hot Knife is an excellent accessory for the artistic minded foam cutter. Double insulated, it heats up in 6 seconds so you are ready to create quickly. The Hot Knife is light, weighing only 2 ½ lbs. It creates smooth, clean cuts so cleanup is easy. Interchangeable blades make it simple to create extraordinary designs in ICA-LITE® EPS foam. Every foam carver needs one of these!


EPS Packaging Items

  • Corners
  • Edge Protectors
  • Flat Pads
  • Custom Cut Pads
  • Specialty Items
  • End Caps
EPS Shapes & Displays

  • Letters of all styles
  • Logos
  • Columns
  • Theatrical Designs
EPS Fabricated Parts

  • Door Cores
  • Wall Panels
  • Roof Panels
  • Concrete Void Fillers
  • Specialty Panels

The possibilities are endless! Visit our photo gallery at for more EPS project ideas. And don’t forget to follow us!