Huntington Solutions uses the most sophisticated materials, technology, and operations available to create EPS and other resin-based products that serve industries across the country.

Below you will find information on our specific capabilities. We are also innovators with a history of developing cutting-edge solutions and are constantly investing in new equipment and ideas.

Contact us to discuss your specific needs and the solutions we can offer you.

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You Want it WHEN?

We’re ready for even your most demanding timeframe. We enjoy a reputation for being the most responsive team in the business!

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Multi-Material Capability

We offer materials that are environmentally friendly, antistatic, flexible, solvent-resistant, moisture-resistant, and more. Our products can be single material, or mixed, such as expanded foam and corrugated combinations. For more information, see our Capabilities.

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Tested and Proven

Our award-winning technical teams have decades of design experience and offer cutting-edge modeling and comprehensive testing services for a range of qualities such as shock absorbency, thermal control, stability and more to ensure our products meet ASTM, ISTA, or your custom specifications.

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No Order is Too Large or Too Small

Our state-of-the-art molding presses make fast work of high-volume orders. Our comprehensive fabrication capabilities also enable cost-effective methods of meeting unique and small-quantity orders. Whether you need one component a month or thousands delivered weekly, we can get you what you need, when you need it, where you need it.

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Product Attributes

We can engineer products to fit your exact specifications. Here is a selection of the qualities we can design for:

  • Size – our facilities can produce shapes as large as 12 feet by 5 feet and as small as 1/2 in by 1/8 in
  • Shock absorbance
  • Vibration dampening
  • Buoyancy
  • Resilience
  • Stability
  • Flexibility
  • Surface resistance
  • Thermal protection
  • Water/oil/moisture resistance
  • Solvent resistance
  • Anti-static surfaces
  • Anti-abrasive surfaces
  • Color
  • Texture
  • Finish
  • Sustainability/Recycled content
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We have extensive experience working with a wide range of materials, from industry standards to cutting-edge polymers. We can source the right material for the job, even if you don’t see it here.

  • Expanded polystyrene (EPS)
  • Expanded polypropylene (EPP)
  • Expanded polyethylene (EPE)
  • High-density polyethylene (HDPE)
  • Cross-linked polyethylene (XLPE)
  • Die-cut polyethylene
  • Polyethylene Foam (open, closed celled, and cross-linked)
  • Ultra-high-molecular-weight Polyethylene (UHMW)
  • Acetal
  • PVC Vinyl
  • Sintra/Celtec foamed PVC
  • Alupanel
  • GeoFoam
  • ARCEL®
  • Gecet®
  • Corrugated paper
  • Corrugated carton
  • Corrugated polypropylene
  • Clear-View® stretch wrapping
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Software Compatibility

We use the most current versions of the following software programs:

  • Autodesk AutoCAD (with standard design suite)
  • VectorCAD
  • Solid Edge Origin
  • Solidworks
  • Mill Wizard (CNC and prototyping)

We can import or export the following file types:

  • dxf
  • dwg
  • dwf
  • 3dwf
  • igs/iges
  • stp/step
  • Vector files
  • eps
  • par
  • sldprt
  • x_t
  • sat
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Design and Testing

Led by some of the most experienced personnel in the industry, Huntington offers in-house 3D modeling, CNC prototyping, and FEA Analysis, as well as comprehensive and cutting-edge testing of a variety of variables (shake, incline, compression, thermal control, flexibility, shock absorbance, etc.) for all our products to meet ASTM, ISTA or your customized specifications.

Processing Capabilities

Huntington Solutions runs a Pioneer flat die cutting table with a maximum width of 82” and bed length of 110”, with the option to run the length continuously or at controlled intervals. Most of our corrugated plastics are processed using a flat die, with options including perforated scores, center beveled scoring rule, serrated or center beveled knife, and all at varying widths and heights to suit the application. We typically source laser cut dies, though we have suppliers for router cut dies for higher volume projects. The dies are sourced locally with a lead time as soon as “next week,” based on complexity and specifications for the type of rule.

We are able to process some XLPE and other foams on the die table as well, although by using the Waterjet we avoid making the edges concave.

We order corrugated plastics to custom sizes to minimize waste from die cutting. The falloff is bailed and recycled.

Our most common method for adhesion is hot melt. We have two reservoirs that operate about 330˚F with two applicators each. Hot melt works well for the adhesion of XLPE foam to corrugated plastic or XLPE–XLPE bonding. EPS, EPP, and EPE foam; sheet PVC; and HDPE can also take a successful bond from hot melt.

Through Huntington Solutions, we have in house access to hot wire cutting for EPS foam. We have two I-Cutters, 3-axis machines running on ball screws and a frame to accept multiple wires for cutting arrays of parts.

Hot wire cutting produces a smooth cut though the foam, whereas cutting EPS using other methods can result in poor quality surfaces and frays.

Huntington Solutions has multiple down cutters for shaving cut shapes to specific lengths.

Abrasive wire cutting is now available for XLPE foams, including high-density foams. So far we’ve tried up to 9#, but we like a challenge! Call us today to find out how we can help you.

Industrial packaging isn’t always self explanatory. A well-labeled packaging solution can offer ease of use for suppliers and line workers, offering instructions such as load/unload direction and part identification.

We print 4” x 6” paper labels for in-house use, and offer vinyl laminated labels for better durability. Or, if you prefer, we will apply your provided labels to your specifications during production.

We primarily use thermosealing (heat sealing) as a method of adhesion between polyethylene foam, either open or closed cell. This application is used by many of our competitors for forming containers from corrugated plastic. The bond may be more aesthetic, but is much less reliable, as only the surfaces are bonded.

Lamination of polyethylene foams or PVC works well in controlled points because of low melting temperatures. Compound shapes achieved through this method are typical for commodity packaging, such as appliances and electronics, when cushioning is required.

Huntington Solutions operates several Dukane model ultrasonic welding stations, run on new Dukane IQ modems. This allows us to operate each station with complete control over variables such as time, energy, and dispersion rate, giving us completely repeatable results. We use ultrasonic welding in place of heat sealing for our corrugated plastic for a dependable bond and complete fusion of material. We are able to also weld sheet PVC, PVC Vinyl, HDPE, polypropylene nylon webbing, and more.

At Huntington Solutions, we run state-of-the art facilities. Our CNC water jet cutting machine enables us to produce prototypes with little turnaround time; we also cut all of our foam on this machine, eliminating the need for tooling, and reducing our process times. We provide a quick turnaround on design, quoting, and sample/prototype making.

Prototypes are carefully designed and assembled by Huntington Solutions engineers. Designers can recreate an existing pack or design a new solution from simple to complex geometries. Prototypes can be transported to customers’ facilities where they can be tested and assessed.

We operate two 3-Axis CNC water jet cutting machines. Our KMT unit uses a translation software to convert 12DXF to NC, and runs using servos to cut a range of about 49.25” x 99.5”.

Our new addition is the 6’x10’ A & V unit, cutting with two heads at 60” or less. This is a stepping unit, with its own translation software and network integration. We’ve upgraded this unit by addition of Hypertherm high-volume cutting heads, opening the range of available cutting diameters. Waterjet cutting is repeatable, reliable, and efficient, processing a wide range of materials from soft foams to non-tempered steel when operating with garnet.

Our foam is kept class-A surface protecting due to the lack of heat when cutting, and we are able to keep tolerances tight within 1/16” through the sheet.