Abstract: A reusable packaging case for an article comprises an inner foam layer having an interior cavity for holding the article. The inner foam layer surrounds at least a portion of the interior cavity. An outer foam layer substantially surrounds the inner foam layer The outer foam layer may have a density greater than the density of the inner foam layer. The inner foam layer may be formed using a plug having the same shape as the article to be later packaged in the case for shipping. The packaging case may optionally contain numerous additional inner foam layers of varying densities and thicknesses. Many substantially identical packaging cases, such as for shipping numerous identical articles coming off of an assembly line, may be formed using the plug.