Abstract: A foam packaging assembly for protecting an article includes one or more pads including at least one corner pad and at least one side pad disposed between the corner pads, a packaging container configured to receive the article or an inner box storing the article, and a configurator determining one or more dimensions of the container based on at least one input variable of the article or the inner box. The configurator further determines a number of the pads for placement inside the container such that the article with the pads is protected during storage or transport. Further, the foam packaging assembly includes at least one insert board configured for placement over the article inside the container, and the configurator determines one or more dimensions of the insert board when the insert board is selected to be disposed inside the container.