Engineered protective cushioning with superior shock absorption, thermoformed from 100% recycled HDPE as standard. Scalable to support higher-volume shipments of fragile products, reducing costs, CO₂, and plastic waste.
Engineered for precise G-force performance and tested in ISTA-certified labs, with ASTM/NEBS testing available. Optimized designs in 100% recycled HDPE use significantly less material than PE, EPE, or EPP foam, while enduring repeated drops and reuse.
Highly nestable cushions stack tightly when not in use, reducing shipping, storage, and handling space by up to 85% compared to foam. Additionally, thermoforming enables economies of scale through higher-volume production.
Reflex™ cushioning uses 100% recycled HDPE as the worldwide standard, turning plastic waste into protective packaging. With their nesting design and durable build, the cushions support repeated use in circular systems.
We turn plastic waste into nestable, protective packaging that is optimized for your needs. 100% recycled HDPE as standard.
Nefab's Reflex™ cushions are highly customized protective packaging solutions made by thermoforming 100% recycled high-density polyethylene (rHDPE) as standard, subject to customer-specific requirements.
Reflex™ cushions are engineered and molded as product-specific components tailored to the shape, size, and support needs of each application. Seamless, contoured forms cradle the product, while mechanical shock is managed through the unique cushion design and the material properties of HDPE.
Reflex cushioning is usually part of a complete packaging solution.
Reflex™ cushioning helps companies replace foam when packing and shipping high-value, shock-sensitive products that typically weigh between ½ kg and 50 kg (110 lbs.). Because the cushions are thermoformed, they deliver the most value in high-volume applications. Reflex™ cushioning can be adapted to many uses across industries such as data infrastructure, semiconductor, healthcare, and energy equipment.
Whether you call it a closed-loop system, a returnable system, or a circular system, Reflex™ cushioning is durable and space-efficient, so it stands up to repeated use cycles while taking up minimal storage and transport space.
The rHDPE cushions are curbside recyclable around the world, making them a responsible choice for one-way shipments.
Unlike some foams and fiber solutions, thermoformed Reflex™ cushions are non-particulating, making them well suited to cleanrooms and data centers.
Nefab partnered with a global healthcare company to make infusion pump packaging more sustainable. Replacing bulky PE foam with Reflex HDPE cushioning cut CO₂ emissions by 62% and reduced total costs by 30%.
A leading data infrastructure company partnered with Nefab to replace PE foam with HDPE thermoformed Reflex cushioning. This led to a 22% cut in CO₂ emissions and a 6% drop in packaging costs, proving cushioning solutions can be sustainable and cost-effective.
A global telecommunications leader significantly optimized its packaging by switching from PE foam to Reflex cushioning for its universal base transceivers. This change to HDPE end cap cushions led to a 47% global reduction in CO₂ emissions and a 43% decrease in total costs.
Engineered for precise protection
Reflex™ cushioning is designed to meet exact G-force performance requirements while using less material than fabricated and molded closed-cell foam solutions such as PE, EPE, and EPP. Each solution is custom-engineered to the individual product, delivering superior shock absorption that outperforms molded fiber, corrugated, and traditional foam packaging.
Reliable performance
Unique cushion geometries and durable rHDPE combine to withstand repeated drops, resist moisture, and stay non-particulating. Reflex™ cushions hold up against environmental stress and deliver consistent protection.
Tested and validated
Reflex™ cushioning is backed by more than 20 years of expertise in engineering design, ISTA testing, material extrusion, and thermoforming. Nefab's engineering teams validate every solution against rigorous performance standards, while streamlined development and manufacturing enable fast, reliable delivery worldwide.
Global leader, local support
Nefab is the global leader in precision-engineered, scalable thermoformed cushioning and the only supplier backed by fully integrated global production and technical support. With operations in 39 countries and 140 locations, we help customers meet regulatory requirements and run efficient supply chains, combining global coordination with local expertise.
Reflex™ cushioning is highly nestable, allowing cushions to stack tightly when not in use and reducing shipping, storage, and handling space by up to 85% compared to foam.
This substantial reduction in volume lowers transport and storage costs in both inbound supply chains and return logistics, while helping reduce CO₂ emissions. It can also improve handling efficiency and significantly increase assembly line efficiency.
In addition, thermoforming enables efficient production in high volumes, making Reflex™ cushioning a scalable solution for global packaging programs.
Reflex™ cushioning leverages circular concepts to minimize its environmental footprint.
All Nefab facilities worldwide now produce Reflex™ cushioning using 100% recycled HDPE as standard, unless otherwise specified by the customer. We work closely with raw material suppliers to ensure this supply of rHDPE. For transparency, the percentage of recycled HDPE is embossed on every part.
rHDPE can be made from post-consumer waste, such as milk jugs, detergent bottles, and shampoo bottles, as well as post-industrial waste such as scrap and manufacturing offcuts. We continue to collaborate with raw material suppliers to increase levels of PCR (post-consumer recycled) content.
HDPE is the second most recycled plastic in the world after PET. It can be recycled up to 50 times more than fiber/paper-based solutions. Unlike foam cushions that commonly end up in landfills, rHDPE is considered curbside recyclable and can usually be recycled in local municipal recycling streams. On all Reflex™ molds and cushions, the required local recycling symbols for rHDPE material are displayed to communicate recyclability.
At the end of the packaging lifecycle, where possible, Nefab offers take-back programs for used Reflex™ cushioning. Once the cushioning has fulfilled its purpose, Nefab can collect and recycle the material for use as raw material in new recycled thermoformed packaging.
Reflex™ cushioning significantly reduces the use of virgin plastic compared with traditional foam cushioning. Its advanced thermoformed design requires less material overall than equivalent foam applications.
Reflex™ cushioning is designed for reusability, thanks to the durable properties of rHDPE, long-lasting cushioning performance, and engineered geometries that enable a nestable structure. Reusing the cushions can significantly reduce total cost of ownership and environmental impact over multiple cycles. Unlike foam, which can occupy up to 10 times more space, Reflex™ cushioning can be collected, returned, and reused more efficiently in circular systems.
Nefab saves environmental and financial resources by optimizing supply chains. We do so by innovating together with our customers to create smarter packaging and logistics solutions while always respecting people and ethical standards.
We provide complete packaging and logistics solutions that reduce total cost and environmental impact throughout the supply chain.
With over 250 engineers in 30 locations globally, we collaborate closely with customers to design, prototype, test, and deliver tailored packaging solutions.
Nefab's solutions reduce carbon footprints by 31%, on average, reflecting our commitment to sustainability within our operations and offerings.
With 75 years of experience and a presence in over 38 countries, we deliver global solutions with local support.
Looking for sustainable cushioning alternatives to foam? Reach out to us today! Our team of experts in more than 39 countries is ready to collaborate, innovate, and deliver solutions tailored to your unique challenges. Contact your local sales representative for more information.
Custom inserts and inner fittings for product securement
What is Reflex™ cushioning made of?
Reflex™ cushioning is thermoformed from 100% recycled high-density polyethylene (rHDPE) as standard, turning plastic waste – such as post-consumer milk jugs and post-industrial scrap – into engineered protective packaging. The percentage of recycled content is embossed directly on every part for full transparency.
Is Reflex™ cushioning a good alternative to foam packaging?
Yes. Reflex™ cushioning is engineered as a sustainable alternative to PE, EPE, and EPP foam, using significantly less material while delivering the same or better shock absorption. Each solution is custom-engineered to precise G-force requirements and tested in ISTA-certified labs. Compared to plastic foam cushioning – such as PE, EPE, and EPP – Reflex™ cushioning offers:
For a paper-based alternative, see FiberFlute™ cushioning ; for traditional foam, see Foam cushioning .
What is thermoforming, and why does Nefab use it for Reflex™ cushioning?
Thermoforming, or vacuum forming, is a manufacturing process in which a plastic sheet is heated until pliable, formed over a mold to create a precise, product-specific shape, then cooled and trimmed into a finished part. Nefab uses this process for Reflex™ cushioning because, compared to foam manufacturing, thermoforming is a cost-effective and efficient process across low to high production volumes. It offers competitive tooling costs and lead times, benefiting from economies of scale as order size grows. The process also supports up to 100% recycled HDPE content, resulting in a durable, non-particulating cushioning solution that's fully recyclable at end of life. Learn more about Nefab's thermoforming process and capabilities.
What product weight range is Reflex™ cushioning designed for?
Reflex™ cushioning is engineered for high-value, shock-sensitive products that typically weigh between 0.5 kg and 50 kg (110 lbs.), making it well suited to applications across data infrastructure, semiconductor, healthcare, and energy equipment.
Is Reflex™ cushioning suitable for high-volume cushioning packaging programs?
Yes, Reflex™ cushioning is particularly well suited to high-volume cushioning packaging programs, combining several compounding advantages:
While thermoforming remains efficient across both low and high MOQs, the combined benefits of nesting and scale make Reflex™ especially valuable for high-volume shipping programs – historically one of the two key deciding factors, alongside product weight, when selecting a plastic foam cushioning solution.
How does Reflex™ cushioning compare to fiber-based cushioning?
Compared to fiber-based cushioning solutions like FiberFlute™ or molded pulp, Reflex™ HDPE cushioning offers several key advantages:
Fiber-based cushioning, such as FiberFlute™, remains a strong renewable and biodegradable choice – particularly for low-to-medium volume or single-use shipments. Reflex™ is typically the better fit when durability, reuse, or cleanroom performance are priorities.
Can Reflex™ HDPE cushions be recycled?
Yes. HDPE is the second most recycled plastic in the world (after PET) and is considered curbside recyclable in most municipal recycling streams worldwide. Required recycling symbols are displayed on every Reflex™ mold and cushion. At end of life, Nefab also offers take-back programs to collect and recycle used cushions into new packaging.
Is Reflex™ cushioning suitable for cleanroom or data center environments?
Yes. Unlike some foam and fiber-based solutions, thermoformed Reflex™ cushions are non-particulating, making them well suited to cleanrooms, data centers, and other environments with strict contamination requirements.
Which industries use Reflex™ cushioning?
Reflex™ cushioning is used across industries including healthcare, data infrastructure, semiconductor, and energy equipment, wherever high-value, shock-sensitive products need reliable, space-efficient protection.
How much storage and shipping space can Reflex™ cushioning save?
Because Reflex™ cushions are highly nestable, they can stack tightly when not in use, reducing shipping, storage, and handling space by up to 85% compared to foam – lowering both transport costs and CO₂ emissions across inbound and return logistics.
How is Reflex™ cushioning tested and validated?
Every Reflex™ solution is engineered to meet precise G-force performance requirements and validated in ISTA-certified labs, with ASTM/NEBS testing available on request. This is backed by more than 20 years of Nefab expertise in engineering design, material extrusion, and thermoforming.
What material options are available for Reflex™ cushioning?
Reflex™ cushioning is highly configurable to match your product, brand, and sustainability requirements:
Can Reflex™ cushioning be customized with logos or brand elements?
Yes. Reflex™ cushions can be embossed with brand logos, symbols, or program identifiers directly onto the part – communicating sustainability initiatives or brand identity at the point of use.