For non-returnable packages in a big quantity the EPS foam packing is well qualified (EPS=expanded polystyrene). Although that for the production of these foams a tool must be fabricated, the effective costs per piece are low (depends from the quantity).
For reusable packages there is the use of EPP approved (EPP=expanded polypropylene). The production of these foams is analog of the EPS but the material is more though and resistent.

They can be elastic, soft or hard, flexible or stiff, light or ultra-light: it seems anything is possible with expanded polypropylene or expanded polystyrene.


Parts from EPS: