Method of forming a cushioning sheet

A method of forming a cushioning sheet comprising:

• forming a plurality of first sockets in a first layer;
• forming a plurality of second sockets in a second layer, each of the second sockets aligned with a corresponding one of the first sockets;
• positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets;
• and
• coupling the first layer to the second layer to retain the plurality of cushioning inserts within the voids;
• wherein:
• positioning the cushioning insert within the void comprises:
• picking up the cushioning insert;
• releasing the cushioning insert onto the first layer;
• locating the cushioning insert in one of the first sockets;
• and
• covering the first layer with the second layer;
• picking up the cushioning insert comprises picking up the cushioning insert with a vacuum roller, the vacuum roller defining an insert indentation and a vacuum port formed in the insert indentation;
• and
• releasing the cushioning insert onto the first layer comprises releasing the cushioning insert from the insert indentation of the vacuum roller.