Abstract: The present invention is directed to molds for making packaging inserts having a pre-selected shape and a method of making the same. The shape of the mold is determined by first pre-selecting the shape of the packing insert. The shape of the packaging insert is dependent on the type of product that will be shipped. Once the shape of the packing insert is determined, the mold is then made by fabricating multiple parts, each part having a pre-selected shape. The shape of each part of the mold is determined such that when the mold is assembled, the mold forms a contiguous inner cavity having the shape (the inner cavity is the negative) of the pre-selected packaging insert. After the mold is assembled, beaded foam material is injected into the mold to form the packaging insert.