I've spent a lot of time searching for and researching different foam types to use. I've narrowed it down to two main types of foams. These foams are not being used by any of the other miniatures storage companies. These are a higher quality and denser types of foam and will allow for some very unique and useful options to the trays.
My old style foam (and the foam used by "the other guys") looks like this:
http://www.wingsofwar.org/forums/att...8&d=1385916864
As you can see, with just a little pressure you can easily compress the foam. This type of foam gives good protection to your minis from bouncing around in the cutouts, but offers little protection to the top layers of minis if something, or someone, should fall on top of them.
One of the new types of foam I'm testing is shown below. As you will see in this photo, the same pressure applied to it hardly makes a dent in the foam at all.
http://www.wingsofwar.org/forums/att...9&d=1385916864
This new type of foam has a much smaller "bubble structure" and gives it great strength. These new style trays should not bend when you load them full of planes and pick them up from one end. It also has a much smoother surface, so some of the pointy bits of your minis will be a lot less likely to get stuck in the foam. The other type (see the next 4 photos below) I'm testing has a larger bubble structure, but is chemically completely different. It has a very nice looking textured surface and will offer great protection in every direction. With both of these new foam types, I'll be able to offer some visual combinations...