Foldable foam packing element

A unitary foam packing element, comprising:

• a single planar piece of foam which is precut with a plurality of score lines to define:
• a first planar portion and a second planar portion, the score lines enabling the first planar portion to be folded over onto the second planar portion to form a flat cavity between the first planar portion and the second planar portion;
• the score lines further defining an end panel adjacent the second planar portion, which end panel is adapted to be folded along a respective one of the fold lines so as to form a first end wall of the flat cavity;
• the single planar piece of foam further including an intermediate portion between the first planar portion and the second planar portion, the intermediate portion forming a second end wall of the flat cavity that is opposite the first end wall when the first planar portion is folded over onto the second planar portion;
• the score lines further defining first and second side panels, the score lines enabling the first and second side panels to be folded along respective ones of the score lines so as to form side walls of the flat cavity;
• wherein the first and second end walls and the side walls of the flat cavity define a first predetermined cavity size:
• each of the score lines defining the end panel and the side panels including at least one tab creating segment so that when the end panel is folded into the first end wall and when the side panels are folded into the side walls, at least one cutout region exists adjacent the first end wall and each of the side walls;
• the score lines further define one or more insert pieces that can be separated from the single planar piece of foam and inserted into the one or more cutout regions to reduce an effective size of the flat cavity, and thereby defining, a second predetermined cavity size smaller than said first predetermined cavity size.

A method of forming a packing element from a single planar piece of foam which is precut with a plurality of score lines defining a first planar portion, a second planar portion, and an end panel adjacent the second planar portion, the method comprising:

• folding the first planar portion over onto the second planar portion to form a flat cavity between the first planar portion and the second planar portion;
• and
• folding the end panel along a respective one of the fold lines so as to form a first end wall of the flat cavity;
• wherein the score lines further define one or more insert pieces that can be separated from the single planar piece of foam, and further comprising separating the insert pieces from the single planar piece of foam, and inserting the insert pieces into the one or more cutout regions to reduce an effective size of the flat cavity.